Toyota - Tundra Access - Workshop Manual - 2001 - 2001

Page 1032 j. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. k. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: ^ Do not maintain lock position for more than 10 seconds. ^ Do not let the fluid temperature become too high. l. Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) m. Connect the pressure feed tube. n. 5VZ-FE engine: Install the air cleaner assembly. o. 2UZ-FE engine: Install the air cleaner assembly with air cleaner hose. p. Bleed the power steering system. Page 494 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Page 5077 FOR SPECIAL SERVICE CAMPAIGN REAR FRAME CROSS MEMBER & LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION 2000-2003 MODEL YEAR TUNDRA Page 3106 b. Reinstall a new accelerator pedal position sensor. 1. Check that the throttle valve is under the condition of the opener opening angle (about 4 °). 2. Install the sensor to the place where is at 20 ° rotated to the left from the specified installation position. 3. Gradually turn sensor clockwise until it touches the throttle valve shaft, and tighten the 3 set screws. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) c. Inspect the accelerator pedal position sensor. 1. Connect the accelerator pedal position sensor connector. 2. Connect the TOYOTA hand-held tester or OBD II scan tool to the DLC3. 3. Turn the ignition switch ON. NOTE: After turning the ignition switch ON, do not depress the accelerator pedal. 4. Check that the ACCEL POS #1 (VPA) voltage of the CURRENT DATA shows the standard value. Standard accelerator pedal position voltage: 0.35 - 0.85 V 4. AFTER INSTALL THROTTLE BODY, INSPECT SYSTEM OPERATION Recall - Rear Cross-Member Corrosion Technical Service Bulletin # SC90M Date: 091116 Page 4134 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 Page 6286 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 839 Page 6729 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2906 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Testing and Inspection Condenser HVAC: Testing and Inspection ON-VEHICLE INSPECTION 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. Page 722 Crankshaft Position Sensor Page 4700 Driver Side J/B And Integration Relay Inner Circuit Page 5809 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1298 1. Remove the engine under cover. 2. Drain the engine coolant. 3. Remove the intake air connector assembly. 4. Remove the radiator fan shroud. 5. Remove the drive belt, fan, fluid coupling, and fan pulley. 6. Without disconnecting the power steering fluid lines, remove the power steering pump. HINT: Suspend the power steering pump securely. 7. Remove the drive belt idler pulley. 8. Remove the right hand (RH) No. 3 timing belt cover. 9. Remove the No.2 timing belt cover. 10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting bracket. HINT: Suspend the A/C compressor securely. 11. Disconnect the A/C compressor mounting bracket. Page 1030 Power Steering Fluid: Testing and Inspection INSPECTION 1. CHECK FLUID LEVEL a. Keep the vehicle level. b. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON(R) II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir/reservoir cap dipstick. If the fluid is cold, check that it is within the COLD LEVEL range. c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. f. With the engine idling, measure the fluid level in the oil reservoir. g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 inch) If a problem is found, bleed power steering system. i. Check the fluid level. Page 2442 CHART 26 Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminals and the switch body with the switch ON (switch pin released: opened door). b. Check that no continuity exists between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. Page 4980 1. INSTALL SPIRAL CABLE 2. INSTALL UPPER AND LOWER COLUMN COVERS 3. INSTALL STEERING WHEEL 4. INSTALL STEERING WHEEL PAD Page 5224 a. Disconnect the stator lead wire from the compressor housing. b. Using SST, remove the snap ring. SST 95994-10020 NOTE: The snap ring should be installed so that its beveled side faces up. c. Remove the stator. REASSEMBLY Reassembly is in the reverse order of disassembly. Locations Engine Room R/B Page 3437 Steps 1 - 2 Page 2886 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 4771 Engine Room R/B Details Page 183 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Page 1595 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Plastic Cap, 108 kPa 1. Remove coolant and any foreign material on 0-ring "A." 2. Check that 0-ring "A" is not deformed, cracked, or swollen. 3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 Page 11 Blower Motor Relay: Testing and Inspection HEATER MAIN RELAY INSPECTION 1. REMOVE HEATER MAIN RELAY FROM NO.2 RELAY BLOCK 2. INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 566 CHART 23 Locations EFI Main Relay: Locations Engine Room R/B Page 2472 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 4135 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. ^ 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. ^ 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Page 4755 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3343 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 608 Page 6355 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1320 4. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) b. Fill with fresh engine oil. Capacity: c. Reinstall the oil filler cap. HINT: Install the oil filler cap facing the direction as shown in the illustration. 5. START ENGINE AND CHECK FOR ENGINE OIL LEAKS 6. RECHECK ENGINE OIL LEVEL 7. w/Oil filter change: REINSTALL ENGINE UNDER COVER Page 2428 CHART 14 Page 4565 7. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. 8. INSPECT THAT FIELD COIL IS NOT GROUNDED Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. 9. 2.0 kW type INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B). Resistance: 1.5 - 1.9 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the field frame. 10. INSPECT BRUSH LENGTH Page 4536 Generator (Part 1) Page 4716 Glossary Of Terms And Symbols (Part 1) Page 1603 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications New gasket and the ECT sensor. Torque: .......................................................................................... .................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf) New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ............................................... .................................................................................................................................. 18 N.m (185 kgf.cm, 13 ft.lbf) Page 69 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2689 Crankshaft Position Sensor Page 167 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Page 3181 Crankshaft Position Sensor Page 2777 CHART 28 Trailer Harness - Updated Design/Diagnostics Trailer Adapter Kit: Technical Service Bulletins Trailer Harness - Updated Design/Diagnostics ACCESSORIES AX006-02 October 18, 2002 Title: TRAILER WIRE HARNESS Models: 4Runner, Highlander, land Cruiser, RAV4, Sienna, Tacoma & Tundra Introduction Beginning in 2000, the accessory trailer wire harness supplier was changed and a new design was adopted which incorporated in-line fuses in the tow wire harness in addition to the vehicle fuse. This bulletin identifies the fuse location to supplement dealer diagnostics troubleshooting. In the future please reference the accessory trailer wire harness Owner's Guide for the vehicle specific diagnostic procedures. As a general note please place the towing wire harness Owner's Guide in glove box after every DIO installation. Applicable Vehicles ^ 4Runner, Highlander, Land Cruiser, RAV4, Sienna, Tacoma, and Tundra vehicles using the Accessory Towing Receiver Hitch and factory Towing Receiver Hitch option. (See table below for applicable model years.) Accessory Wire Harness Kit Information Warranty Information Page 6425 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2327 Engine Control Module: Specifications Terminals Of ECU - Connector Pinouts (Part 2) Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminals and the switch body with the switch ON (switch pin released: opened door). b. Check that no continuity exists between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. Page 3474 Transmission Mode Indicator - A/T: Testing and Inspection ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 4, 7, 8 - GROUND : Approx. 13 Ohms O4 O/D MAIN SW 3 - 1 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S4 STOP LIGHT SW 1 - 2 : Closed with brake pedal depressed E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position S2, SL - E1 : 0 - 1.5 volts with vehicle not move STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F) OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F) VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with ignition SW on and throttle valve fully open VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off SPD - E1 : Pulse generation with vehicle moving 2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position +B - E1 : 9 - 14 volts with ignition SW at ON or ST position BATT - E1 : Always 9 - 14 volts P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever in 2 position 3 - 8 : Closed with shift lever in L position Page 3744 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 3269 Step 3 Brakes - Rear Brakes Vibrate Upon Application Brake Drum: Customer Interest Brakes - Rear Brakes Vibrate Upon Application BRAKES BR003-02 REVISED Title: REAR BRAKE VIBRATION Models" '00 - '05 Tundra September 16, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. Parts Informations table has been updated. Required SSTs table has been added. The Warranty Information has been updated. The Diagnosis Procedure and Repair Procedure have been combined into one Repair Procedure section. The Repair Procedure section has been updated. PLEASE READ ENTIRE TSB. The previous TSB should be discarded. Introduction New brake drums have been introduced for use as service parts on 2000 - 2005 model year Tundra trucks to reduce rear brake vibration. The new drum has increased mass and rigidity. Applicable Vehicles 2000 - 2005 model year Tundra vehicles. Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Applicable Warranty*: The replacement of the Rear Axle Shaft is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3019 a. Disconnect the vacuum hose from intake air resonator. b. Disconnect the fuel return hose from the pressure regulator. CAUTION: Put a shop towel under the pressure regulator. c. Remove the 2 bolts, and pull out the pressure regulator. d. Remove the O-ring from the pressure regulator. INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR a. Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. b. While turning the pressure regulator left and right, install it to the delivery pipe. c. Install the pressure regulator with the 2 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 2413 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection 5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire harness side connector. Capacity Specifications Refrigerant: Capacity Specifications Charge Volume 600 +/- 50 g Page 5592 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 6816 Horn: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6348 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5385 Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG MANUAL ON-OFF SWITCH Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the passenger airbag manual on-0ff switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the front passenger airbag is disabled, OFF indicator inside the switch will light up. Page 6006 Page 2679 Engine Coolant Temperature (ECT) Sensor Page 6388 w/o Tachometer If resistance value is not as specified, replace the receiver gauge. Page 4609 Cigarette Lighter And Power Outlet Page 6495 Splice Location B11 Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST w/ INTERMITTENT If continuity is not as specified, replace the switch. Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2523 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Page 625 CHART 20 Page 3521 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Page 3018 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator REMOVAL REMOVE FUEL PRESSURE REGULATOR Page 842 Locations Anti-Lock Brake System Page 5699 Page 4972 Supplemental Restraint System Page 4365 8. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. 09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. Page 6501 12 - GROUND : Approx. 12 volts for 0.2 seconds with following operations - Door lock control SW unlocked - Door lock control SW looked with ignition key in cylinder and LH door open (Ignition key reminder function) - Door lock knob locked with ignition key in cylinder and LH door open. (Ignition key reminder function) - Unlocking the LH, RH door cylinder with key 13 - GROUND : Approx. 12 volts for 0.2 seconds with following operations - Door lock control SW locked - Locking the LH, RH door cylinder with key 14 - GROUND : Continuity with front LH door open (Standard cab) 14 - GROUND : Continuity with each LH door open (Access cab) 15 - GROUND : Continuity with front RH door open (Standard cab) 15 - GROUND : Continuity with each RH door open (Access cab) D16, D17 DOOR COURTESY SW FRONT LH, RH 1 - GROUND : Closed with door open D22, D23 DOOR KEY LOCK AND UNLOCK SW LH, RH 1 - 2 : Closed with door lock cylinder locked with key 3 - 2 : Closed with door lock cylinder unlocked with key D25, D26 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW LH, RH 4 - 1 : Closed with door lock knob UNLOCK position U1 UNLOCK WARNING SW 1 - 2 : Closed with key in cylinder Page 2511 Oxygen Sensor: Description and Operation Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Engine Controls - Error When Reprogramming ECU Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Ground Locations Transmission Mode Indicator - A/T: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 408 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1993 Page 2430 CHART 16 CHART 17 Diagrams Radiator: Diagrams RADIATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Part 1 of 2 Page 3376 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 5940 Page 25 Audible Warning Device Control Module: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Specifications Drain Plug: Specifications Drain Plug 20 Nm Page 176 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Page 2841 Heated Oxygen Sensor Page 3758 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Testing and Inspection Hazard Warning Switch: Testing and Inspection INSPECT HAZARD WARNING SWITCH CONTINUITY a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster integration. c. Check that continuity exists between terminal 17 and terminal 1 with the switch ON. d. Check that no continuity exists between terminal 17 and terminal 1 with the switch OFF. If continuity is not as specified, replace the switch. Page 6818 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2829 CHART 25 Testing and Inspection Interior Light Switch: Testing and Inspection INSPECT FRONT PERSONAL LIGHT SWITCH CONTINUITY a. Disconnect the connector from the personal light. b. Push the personal light switch ON, check that continuity exists between terminal 3 and body terminal 1. c. Turn the light switch to DOOR, check that continuity exists between terminal 2 and 3. If operation is as specified, replace the switch. INSPECT ROOM LIGHT SWITCH a. Disconnect the connector from the interior light assembly. b. Turn the interior light switch ON, check that continuity exists terminal 2 and body ground. c. Turn the interior light switch to DOOR, check that continuity exists between terminals 1 and 2. If operation is not as specified, replace the switch. Page 5725 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 4413 20 seconds. If the brake pedal does not return, replace the ABS actuator because the motor operation is in failure. h. Turn the motor relay OFF and release the brake pedal. 4. INSPECT OTHER WHEEL SOLENOIDS OPERATION Check the solenoids of the other wheels with the same inspection procedure as the right front wheel solenoids. HINT: Left front wheel: SFLH and SFLR Both rear wheels: SRRH and SRRR NOTICE: Never depress the brake pedal under the condition that the reduction solenoid alone is turned ON as ABS ECU is reset. 5. CLEAR DTC Page 5045 Page 510 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Page 253 Fuel Pump Relay: Testing and Inspection Circuit Opening Relay CIRCUIT OPENING RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN) 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL RELAY BOX COVER Page 3453 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 1188 Crankshaft crank pin diameter Standard sized bearing center wall thickness Page 1449 Timing Belt Idler Pulley: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Timing Belt; Service and Repair. Page 6658 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Paint - Refinishing Information Paint: Technical Service Bulletins Paint - Refinishing Information COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: TOPCOAT SAND & POLISH SECTION: REFINISH BULLETIN # 173 MODELS: ALL TOYOTA LEXUS AND SCION DATE: APRIL 2009 Customers have high expectations for automotive paint finish appearance and expect repairs to match factory color gloss and texture. Flawed refinish appearance is a cause of concern and will likely have a negative affect on customer satisfaction and retention. Toyota recognizes the reality of paint finish application in the shop environment. In addition to color matching and blending countermeasures to remove paint process intrusion (dirt nibs) are necessary to achieve an undetectable finish match. This is also common in manufacturing plants when process intrusion is encountered. Countermeasures are defined as; ultra-fine sanding to level nibs followed by polishing to a level of gloss and texture consistent with the original finish. Technicians undertaking these tasks should review applicable technical data sheets for product process and handling instructions as well as applicable safety information. Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and Lexus L101 Paint Finish Repair training. Please visit for scheduling and registration information. Page 3919 Transmission Mode Indicator - A/T: Testing and Inspection ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 4, 7, 8 - GROUND : Approx. 13 Ohms O4 O/D MAIN SW 3 - 1 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S4 STOP LIGHT SW 1 - 2 : Closed with brake pedal depressed E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position S2, SL - E1 : 0 - 1.5 volts with vehicle not move STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F) OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F) VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with ignition SW on and throttle valve fully open VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off SPD - E1 : Pulse generation with vehicle moving 2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position +B - E1 : 9 - 14 volts with ignition SW at ON or ST position BATT - E1 : Always 9 - 14 volts P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever in 2 position 3 - 8 : Closed with shift lever in L position Page 5409 1. INSTALL SPIRAL CABLE 2. INSTALL UPPER AND LOWER COLUMN COVERS 3. INSTALL STEERING WHEEL 4. INSTALL STEERING WHEEL PAD Restraints - Seat Belt Tongue Plate Stopper Replacement Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Tongue Plate Stopper Replacement T-SB-0258-08 September 2, 2008 Seat Belt Tongue Plate Stopper Replacement Service Category Vehicle Interior Section Seat Belt Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. BO017-07. ^ Applicability has been updated to include 2008 model year vehicles. TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction For situations where only the seat belt stopper is broken a new service part has been developed to eliminate the need to replace the entire seat belt assembly. Follow the installation procedure below to utilize this new part. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 4776 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST w/ INTERMITTENT If continuity is not as specified, replace the switch. Page 1086 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Testing and Inspection Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise, check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Testing and Inspection Windshield Washer Motor: Testing and Inspection INSPECT WASHER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the motor operates. NOTE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. Locations Vapor Pressure Sensor Page 3246 Transmission Mode Indicator - A/T: Description and Operation ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR SYSTEM OUTLINE The electronically controlled transmission electrically controls the, throttle pressure, lock-up pressure, and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls the gear shift timing and lock-up timing in response to the vehicle's driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection of the gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. GEAR SHIFT OPERATION When driving, the engine warm up condition is input as a control signal from the engine coolant temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA, VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. LOCK-UP OPERATION When the engine control module decides based on each signal that the lock-up condition has been met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the electronically controlled transmission solenoid to GROUND. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input to TERMINAL STP of the engine control module. As a result, the engine control module cuts the current to the solenoid to release the lock-up. 4. OVERDRIVE CIRCUIT - O/D main SW on When the O/D main SW is switched to ON position, a signal is input to TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range, through the control of the engine control module. - O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range through the control of the engine control module. When in the overdrive range already, shift down is made. Page 1445 31. RECHECK ENGINE COOLANT LEVEL 32. INSTALL ENGINE UNDER COVER Page 6886 Lamp Control Module: Electrical Diagrams Service Hints LIGHT AUTO TURN OFF HEAD RELAY 2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position. Closed with the engine running and the parking brake lever released (w/ daytime running light) C15 LIGHT CONTROL SW [COMB. SW] 13 - 16 : Closed with light control SW at HEAD position 14 - 16 : Closed with light control SW at TAIL or HEAD position D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Continuity with the front LH door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with the ignition SW at ON position 14 - GROUND : Continuity with the front LH door open 3, 6 - GROUND : Always approx. 12 volts 8 - GROUND : Always continuity ILLUMINATION C15 LIGHT CONTROL SW [COMB. SW] 14 - 16 : Closed with light control SW at TAIL or HEAD position Page 2354 Windows 2000 SP2 or later Windows XP Pro SP1 or later For more information about the J2534 devices listed above, contact the vendors. To report compatibility problems with listed hardware/software, please contact the device manufacturer. For more information about Toyota vehicle reprogramming CDs or to report problems running Toyota's Calibration Update Wizard software, please contact Toyota. OBTAINING A CALIBRATION CD The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the Calibration Update Wizard application software for a Windows PC, and instructions for use. Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N 00456-REPRG-001. IMPORTANT NOTICE It is possible to permanently damage a vehicle controller during the flash reprogramming process. It is especially important to understand that once started, the reprogramming process must not be interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go into standby, hibernation or similar power management modes. The information provided herein is intended expressly for use by qualified professional automobile technicians. To prevent damage to your customer's vehicle and ensure safe service practice, read these materials completely and thoroughly before servicing the vehicle and be sure to follow all instructions. Page 3439 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 5073 Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 1365 11. REINSTALL ENGINE UNDER COVER Page 2576 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 5611 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Specifications Timing Belt: Specifications Timing Belt Replacement Interval ........................................................................................................ ............................................................. 90,000 miles No.2 Timing Belt Cover Torque ........................................................................................................... ...................................................................... 16 Nm RH No.2 Timing Belt Cover Torque .................. ........................................................................................................................................................ 7.5 Nm LH No.3 Timing Belt Cover Torque ............................................................................................... ........................................................................... 7.5 Nm Page 5221 1. 5VZ-FE engine INSTALL COMPRESSOR a. Install the compressor with the 4 bolts. Torque: 25 N.m (250 kgf.cm, 18 in.lbf) b. Connect the connector. 2. 2UZ-FE engine INSTALL COMPRESSOR a. Install the compressor with cooler bracket with the 4 bolts and nut. Torque: 25 N.m (250 kgf.cm, 18 in.lbf) b. Connect the connector. 3. 5VZ-FE engine CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with the 2 bolts. Torque: 10 N.m (100 kgf.cm, 7 in.lbf) NOTE: Hose should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O-rings with compressor oil and install them to the hoses. 4. 2UZ-FE engine CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with the 2 nuts. Torque: 10 N.m (100 kgf.cm, 7 in.lbf) NOTE: Hose should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O-rings with compressor oil and install them to the hoses. 5. INSTALL AND CHECK DRIVE BELT 6. 5VZ-FE engine INSTALL ENGINE UNDER COVER 7. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY 8. EVACUATE AIR FROM REFRIGERATION SYSTEM 9. CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 10. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. Locations Instrument Panel Page 3490 Steps 1 - 2 Page 4924 Glossary Of Terms And Symbols (Part 1) Page 2825 Page 99 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Engine - Squealing Noise On Cold Start Up Drive Belt: All Technical Service Bulletins Engine - Squealing Noise On Cold Start Up ENGINE EG003-05 Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '05 Tundra & '01 - '05 Sequoia February 9, 2005 Introduction Some customers may experience abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt has been developed to correct this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. ^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Replace the accessory drive belt with the improved part. 1. Remove existing accessory drive belt. Locations Lower Side Moulding / Trim: Locations Body Outside Moulding Page 2122 5. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3. Page 6817 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 918 13. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY a. Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley. 14. SET TIMING BELT TENSIONER a. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbs.) of pressure. b. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. c. Release the press. d. Install the dust boot to the belt tensioner. 15. INSTALL TIMING BELT TENSIONER a. Temporarily install the belt tensioner with the 2 bolts. b. Alternately tighten the 2 bolts. Torque: 26 Nm (270 kgf-cm, 19 ft. lbs.) c. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner. 16. CHECK VALVE TIMING a. Temporarily install the crankshaft pulley bolt. b. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTICE: Always turn the crankshaft pulley clockwise. Page 467 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 6166 ^ To reduce wind noise, the shape of the mouldings has been optimized, and a deflector has been provided below the front bumper to ensure a smooth airflow. Weatherstrip Page 4514 ^ Both share the same charge and discharge principles. ^ Both are safely charged by vehicle charging systems. ^ When discharged, both can be recharged at high current levels. Battery Charging Information Damage to AGM batteries becomes an issue when the charge rate is NOT monitored and controlled by the charger (i.e., quick chargers). The performance of an AGM battery can be irreversibly reduced if the charge rate remains too high, allowing the battery to overheat and vent. Once an AGM battery loses water (venting), the glass mats will become dry, causing the battery to lose conductance, power, and performance. In most vehicle charging systems, the alternator limits the charging rate by limiting the output voltage (about 14.4V). For example, an AGM battery may be observed charging at 60A and 13.5V. As the battery recharges, the charging voltage will increase from 13.5V to approximately 14.4V (voltage will vary based on temperature, control sophistication, etc.), and the current will decrease from 60A to about OA. The charging system voltage regulators prevent both AGM and flooded lead acid batteries from being overcharged and venting. By controlling the voltage, the charging rate (current) can be controlled. The discontinued Special Service Tool (SST) Automatic Trickle Charger (SST P/N 00002-YA122-01) maintained a manual charging limit of 10A to accomplish a safe recharge rate for AGM batteries. This low amp charge was low enough to prevent the AGM battery from overheating and venting since the charger had no way of monitoring battery temperature/condition. The GR8 Battery Diagnostic Station (SST P/N 00002-MCGR8) is a customized diagnostic fast charger that monitors battery temperature/conditions and contains custom charging rates for ALL model batteries used for Toyota and Scion vehicles. As such, it safely charges good batteries as fast as possible to a point where they can be returned to service and eliminates wasted charging time by quickly diagnosing bad batteries. Based on the characteristics and performance measures of each individual battery (i.e., custom charging rate), the GR8 Battery Diagnostic Station will apply the fastest charging rate that is safe for that particular battery. ^ When the GR8 Battery Diagnostic Station pe~ormance measurements indicate that an AGM battery qualifies for fast-charging, it will be charged at whatever current level it will accept, but the charging voltage will be controlled so that it does NOT exceed 14.4V, and the battery temperature will NOT exceed 135°F (57°C). ^ When the GR8 Battery Diagnostic Station performance measurements indicate that an AGM battery does NOT qualify for fast-charging, the charge session will only continue if the battery qualifies for "Recovery" mode (part of which means, NO defects or other serious performance issues were found). It is recommended that ALL Toyota and Scion vehicle batteries be charged using the GR8 Battery Diagnostic Station. NOTE: ^ NEVER connect the GR8 Battery Diagnostic Station to remote battery terminals. ^ ALWAYS connect the GR8 Battery Diagnostic Station DIRECTLY to the vehicle battery. For assistance on charging procedures, refer to the GR8 Instruction Manual or TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery". The GR8 Instruction Manual can be found on the Technical Information System (TIS), Diagnostics Battery - "GR8 Instruction Manual". Page 4726 Cigarette Lighter And Power Outlet Page 3995 20 seconds. If the brake pedal does not return, replace the ABS actuator because the motor operation is in failure. h. Turn the motor relay OFF and release the brake pedal. 4. INSPECT OTHER WHEEL SOLENOIDS OPERATION Check the solenoids of the other wheels with the same inspection procedure as the right front wheel solenoids. HINT: Left front wheel: SFLH and SFLR Both rear wheels: SRRH and SRRR NOTICE: Never depress the brake pedal under the condition that the reduction solenoid alone is turned ON as ABS ECU is reset. 5. CLEAR DTC Page 3202 Spark Plug: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT SPARK PLUGS a. Remove the ignition coils (with igniter). b. Using a 16 mm plug wrench, remove the spark plugs. c. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. Recommended Spark Plug Page 1235 4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe. 5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. 6. Check if there is any fuel leakage. h. Observe these precautions when handling nylon tube. 1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by bending it. i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 6194 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch Page 1022 Engine Oil: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection; Procedures. Page 4323 INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. 09023-00100 Page 5047 Page 6302 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 5535 Sample Seat Belt Extender Customer Information Label Front Seat Belt Extender Applications Page 5782 Trailer Towing Page 607 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 5926 Page 838 Page 6248 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 2585 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 662 Vehicle Speed Sensor NO.2 Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Page 4800 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT BRAKE LINE Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) Page 6524 Glossary Of Terms And Symbols (Part 2) Page 2869 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 836 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 6038 least once a month to lubricate the compressor. 1. Turn off A/C and blower switches prior to starting engine. 2. Start and warm up the engine until engine idle drops below 1,000 rpm. 3. Turn on the A/C system (including the rear A/C) using the following settings: A. A/C Switch: On B. Blower Speed: High C. Engine Speed: Below 1,000 RPM 4. Keep A/C on with engine idling for at least one minute (in dual A/C vehicles leave on for two minutes). 5. Turn off A/C system and stop engine. Disk Brake Rotor Surface Rust Removal The brake rotors are made of cast iron so they may show gradual build-up of surface rust during long term storage. At least once every two months drive the vehicle and use the brakes normally stopping from about 30 mph at least 20 times. This regular usage will help prevent severe rust build up and the possibility of unwanted brake vibration concerns due to rust. NOTE ^ If the brake vibration still occurs after the braking cycle, determine the root cause of the brake vibration and repair. ^ Brake rotor resurfacing may be required if the rust was severe and resulted in excessive rotor thickness variation. Page 4982 c. Using a service-purpose wire harness tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 sq.mm or more (0.0019 sq.in. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 sq.mm (0.0019 sq.in). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x sq.(Diameter) divided by 4 1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35. mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTE: Tighten the bolts by hand until the bolts become difficult to turn. - Do not tighten the bolts too much. Page 6282 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 1919 CHART 11 Page 2775 CHART 27 Page 2240 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 2828 CHART 24 Page 2300 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Page 911 a. Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates aligned. If not, turn the crankshaft 1 revolution (360°). c. Remove the crankshaft pulley bolt. NOTICE: Do not turn the crankshaft pulley. 17. REMOVE TIMING BELT TENSIONER HINT: - When re-using timing belt: If the installation marks have disappeared, before remove the timing belt, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys. - When replacing timing belt tensioner only: To avoid meshing of the timing pulley and timing belt, secure one of them with string. And place matchmarks on the timing belt and RH camshaft timing pulley. Page 2500 CHART 26 Page 1607 Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT 11. REINSTALL THROTTLE BODY COVER Page 869 2. Tighten the union bolt by hand. 3. Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. Page 4540 4. INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. 5. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the coil leads and drive end frame. If there is continuity, replace the drive end frame assembly. 6. INSPECT EXPOSED BRUSH LENGTH Using vernier calipers, measure the exposed brush length. If the exposed length is less than minimum, replace the brush holder assembly. 7. INSPECT POSITIVE RECTIFIER Page 3191 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Service and Repair Piston Pin: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 4213 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Page 2999 4 nuts holding the delivery pipes to the lower intake manifold. Torque:..............18 N.m (185 kgf.cm, 13 ft.lbf) Page 1436 Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. 18. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS a. Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise. SST 09960-10010 (09962-01000, 09963-01000) b. Disconnect the timing belt from the camshaft timing pulleys. 19. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt and timing pulley. Remove the 2 timing pulleys. SST 09960-10010 (09962-01000, 09963-01000) 20. REMOVE GENERATOR 21. REMOVE DRIVE BELT TENSIONER Remove the bolt, 2 nuts and belt tensioner. 22. REMOVE CRANKSHAFT PULLEY Using SST, remove the crankshaft pulley. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020) NOTICE: Do not turn the crankshaft pulley. 23. REMOVE NO.1 TIMING BELT COVER Remove the 4 bolts and timing belt cover. Page 2246 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 2878 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Page 4892 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 3749 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 6167 The location and the cross section of the weatherstrips have been optimized to ensure a high level of sealing performance and sound insulation. Cab Mounting Page 5764 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 6333 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 2401 Engine Bank Identification Page 2769 Page 1065 Fuse: Application and ID Engine Room R/B Fuse Applications (Part 1) Page 5661 1. LH: REMOVE FRONT AIRBAG SENSOR a. 2UZ-FE: Remove the battery carrier, battery and battery tray. b. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with sensor assembly installed. c. Remove the 2 bolts and front airbag sensor. 2. RH: REMOVE FRONT AIRBAG SENSOR a. Remove the air cleaner assembly. b. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with sensor assembly installed. c. Remove the 2 bolts and front airbag sensor. INSTALLATION INSTALL FRONT AIRBAG SENSORS Page 5945 Specifications Locations Impact Sensor: Locations Front Airbag Sensor Page 2483 CHART 10 ABS/TCS - Zero Point Calibration Information Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 1708 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Locations Supplemental Restraint System Page 2818 CHART 15 Page 5780 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Brakes - Vibration From Front Brakes Technical Service Bulletin # BR004R-02 Date: 040924 Brakes - Vibration From Front Brakes BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra September 16, 2002 TSB REVISION NOTICE: ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque speification, step 24, was changed. ^ September 8, 2003: A torque specification, step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. On-Vehicle Inspection Fuel Injector: Testing and Inspection On-Vehicle Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. INSPECT INJECTOR RESISTANCE a. Disconnect the 8 injector connectors. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 - 14.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the injector. c. Reconnect the 8 injector connectors. 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Page 4411 Part 2 of 2 Page 115 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Page 732 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Page 5571 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3293 c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 4LO position. d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO -> 4HI position. HINT: When inspecting the operation described, use a heater main relay. NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing. Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6062 Warning: Auto Magic © Special Cleaner Concentrate is a corrosive material. Appropriate personal protection equipment must be worn to protect persons performing the contamination removal procedure. Please refer to the precautions on the product prior to use. Caution: Consult local or state regulations regarding the handling, use, and disposal of Auto Magic © Special Cleaner Concentrate prior to use. Under no circumstances should contamination removal be performed in direct sunlight or contamination removal solution be allowed to dry on vehicle surfaces, as staining of plastic, rubber, or painted parts may result. Repair Procedure 1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rinse again thoroughly with fresh water. 2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any other surface. Apply the diluted cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface. 3. Thoroughly rinse vehicle with fresh water. 4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the wash several times if necessary to achieve complete removal. 5. Dry vehicle with a soft terry cloth towel and apply a non-abrasive non-silicone glaze to obtain a high-gloss finish. Page 3760 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2066 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 5246 1. REMOVE CENTER CLUSTER INTEGRATION PANEL a. Remove the 3 heater control knobs. b. Remove the 5 screws. c. Remove integration control panel by pulling the portions indicated by arrows in the illustration. d. Disconnect the connector. 2. REMOVE LOWER LH FINISH PANEL 3. REMOVE HEATER TO REGISTER DUCT NO.2 4. REMOVE GLOVE COMPARTMENT DOOR 5. REMOVE LOWER NO.2 FINISH PANEL 6. REMOVE HEATER TO REGISTER DUCT NO.4 7. DISCONNECT HEATER CONTROL CABLES Page 5581 Key Reminder And Seat Belt Warning Service and Repair Fuel Pressure Release: Service and Repair SFI SYSTEM PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector. b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. Page 1043 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Page 234 Engine Control Module: Connector Views Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Page 4915 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 3587 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Page 2590 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 1937 CHART 27 Page 86 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 1933 CHART 25 Specifications Timing Belt: Specifications Timing Belt Replacement Interval ........................................................................................................ ............................................................. 90,000 miles No.2 Timing Belt Cover Torque ........................................................................................................... ...................................................................... 16 Nm RH No.2 Timing Belt Cover Torque .................. ........................................................................................................................................................ 7.5 Nm LH No.3 Timing Belt Cover Torque ............................................................................................... ........................................................................... 7.5 Nm Page 1761 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Locations Supplemental Restraint System Page 2972 Mass Air Flow (MAF) Meter Page 2595 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Engine - Accessory Drive Belt Squealing Noise Drive Belt: All Technical Service Bulletins Engine - Accessory Drive Belt Squealing Noise ENGINE EG026-06 REVISED Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '06 Tundra April 21, 2006 TSB REVISION NOTICE: ^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered. Previous versions of this TSB should be discarded. Introduction Some customers may experience an abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor bracket, and revised installation procedure have been developed to address this condition. Applicable Vehicles ^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Parts Information Warranty Information Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 2393 Engine Bank Identification Page 2229 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 5576 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 5543 To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the extender and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. SRS/Interior - Seat Cover Replacement Caution Seat Cover: All Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution BODY BO014-05 Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES Models: '98 - '06 All Models November 10, 2005 TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now obsolete and should be discarded. Introduction Beginning in 1998, Toyota introduced side airbags as optional equipment. Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or other seat cover materials on vehicles due to the following: ^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in part, during an accident. ^ Modifications that negatively affect side airbag performance can result in severe occupant injuries. ^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety system. ^ The design of the seat is complex, integrating safety and strength with comfort and luxury. *NOTE: Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used due to the effect on proper airbag performance. Toyota strongly discourages modifying original equipment seats that have optional side airbags. Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident. Applicable Vehicles ^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags. Warranty Information Page 3583 Transmission Mode Indicator - A/T: Testing and Inspection ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 4, 7, 8 - GROUND : Approx. 13 Ohms O4 O/D MAIN SW 3 - 1 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S4 STOP LIGHT SW 1 - 2 : Closed with brake pedal depressed E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position S2, SL - E1 : 0 - 1.5 volts with vehicle not move STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F) OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F) VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with ignition SW on and throttle valve fully open VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off SPD - E1 : Pulse generation with vehicle moving 2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position +B - E1 : 9 - 14 volts with ignition SW at ON or ST position BATT - E1 : Always 9 - 14 volts P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever in 2 position 3 - 8 : Closed with shift lever in L position Page 3229 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3614 Part 1 of 2 Part 2 of 2 Page 5071 Service and Repair Input Shaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transfer Case; Service and Repair. Page 4641 Fuse Block: Connector Views Engine Room R/B Page 4973 Steering Wheel: Service Precautions SRS AIRBAG PRECAUTION TOYOTA vehicles are equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag, side airbag, curtain airbag (if equipped), and seat belt pretensioner. 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 notices in RESTRAINT SYSTEMS.See: Restraint Systems Page 22 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 3238 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2216 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Brakes - Front Brake Caliper Identification Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification BRAKES BR001-03 REVISED January 8, 2003 Title: FRONT BRAKE COMPONENT IDENTIFICATION Models: '00 - '05 Tundra, '01 - '05 Sequoia TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now obsolete and should be discarded. TSB REVISION NOTICE: March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note" added. The previous TSB should be discarded. Introduction There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are intended to assist you in identifying and ordering the correct replacement pads and fitting kits. Applicable Vehicles: ^ 2000 - 2005 model year Tundra vehicles. ^ 2001 - 2005 model year Sequoia vehicles. Warranty Information Page 6885 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5929 Page 3127 Camshaft Position Sensor Page 5515 Seat Belt Specifications Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 1443 c. Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it. 17. TIGHTEN CRANKSHAFT PULLEY BOLT Using SST, install the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 245 Nm (2,500 kgf-cm, 181 ft. lbs.) 18. INSTALL FAN BRACKET Install the fan bracket with the 2 bolts and 2 nuts. Torque: 12 mm head 16 Nm (160 kgf-cm, 12 ft. lbs.) for (A) 14 mm head 32 Nm (330 kgf-cm, 24 ft. lbs.) for (B) HINT: Each bolt length is indicated in the illustration. Bolt Length: 106 mm (4.17 inch) for 12 mm head (A) 114 mm (4.49 inch) for 14 mm head (B) 19. w A/C: INSTALL A/C COMPRESSOR 20. INSTALL NO.2 TIMING BELT COVER Install the No.2 timing belt cover with the 2 bolts. Page 5728 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2294 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Locations Engine Room R/B Page 5456 Airbag Sensor Assembly Page 5276 1. Turn the temperature control knob to the full cold position. 2. Inspect the clearance between the water control valve lever and the lever stop. If the lever does not contact the lever stop, proceed to step 3. 3. If the lever does not contact the lever stop: A. Disengage the cable retaining clip. B. Pull up on the cable sheath until the water control valve lever contacts the lever stop. C. Re-fasten the cable retaining clip. Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure at Idle .............................................................................................................................. ........................................................................ 29 kPa Oil Pressure at 3000 rpm ............................... .................................................................................................................................................... 294-588 kPa Page 4299 11. 4WD: Remove oil seal (inside). A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration above). B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. Remove axle hub from steering knuckle. A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. SST P/N: 09710-28012-01 (09710-07031) SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. Remove bearing from steering knuckle. Page 4837 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). INSPECTION 1. MEASURE VEHICLE HEIGHT Measuring points: A: Ground clearance of the front drive shaft center B: Ground clearance of the front adjusting cam bolt center C: Ground clearance of the leaf spring front side bushing center D: Ground clearance of the rear axle shaft center Vehicle height: Front: A - B Rear: C - D NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER Testing and Inspection Tail Lamp Relay: Testing and Inspection w/ Daytime running light: INSPECT TAILLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 5136 Page 3469 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 563 CHART 21 Page 3362 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 1984 CHART 12 CHART 13 Page 5378 2. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the airbag sensor assembly connectors. NOTE: Disconnect the connectors with the sensor assembly installed. b. Using a torx wrench, remove the 4 screws. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) c. Remove the airbag sensor assembly. INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. - Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. - Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with 4 screws. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) b. Connect the airbag sensor connectors. NOTE: Connection of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed with the specified torque. - If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. - When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installing , shake the sensor assembly to check that there is no looseness. 2. INSTALL LOWER CENTER COVER Page 913 24. REMOVE TIMING BELT GUIDE 25. REMOVE TIMING BELT COVER SPACER 26. REMOVE TIMING BELT HINT: If re-using the belt and the installation mark has disappeared from it, place a new installation mark on the timing belt to the match the dot mark of the crankshaft timing pulley. 27. REMOVE NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY a. Using a 10 mm hexagon wrench, remove the bolt, No.1 idler pulley and plate washer. b. Remove the bolt and No.2 idler pulley. 28. REMOVE CRANKSHAFT TIMING PULLEY Using SST, remove the timing pulley. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) NOTICE: Do not turn the timing pulley. INSPECTION Page 683 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Page 53 Headlamp Relay: Testing and Inspection POWER SOURCE HEATER RELAY 1 - 2 : Closed with ignition SW on and heater blower SW on HEAD RELAY 2 - 1 : Closed with light control SW at HEAD position or dimmer SW at FLASH position Closed with engine running and parking brake lever released (w/ daytime running light) I23 IGNITION SW 2 - 3 : Closed with ignition key at ACC or ON position 2 - 4 : Closed with ignition key at ON or ST position 7 - 6 : Closed with ignition key at ON or ST position DIMMER RELAY (w/ DAYTIME RUNNING LIGHT) 4 - 3 : Closed with HEAD relay on and dimmer SW at HIGH or FLASH position Page 4094 B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. NOTE: Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of brake vibration on this vehicle. G. Determine if TSB BROO4-02 has already been performed. Repair Procedure No. 1 1. Remove the front wheel. 2. 2WD: Using a screwdriver and hammer remove the grease cap. 3. 4WD: Disconnect drive shaft. A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. Page 5155 1. INSTALL NEW BEARING a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a new snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat MP grease to the oil seal lip. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS) NOTICE: Do not scratch the serration of the speed sensor rotor. 5. 2WD: INSTALL NEW LOCK NUT a. Using SST install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) b. Using a chisel and hammer, stake the lock nut. Page 1772 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 3444 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 1078 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5615 B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Page 2425 CHART 10 Page 4720 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Locations Page 3222 Splice Location B11 Page 1625 Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. w/ Tachometer Page 1141 8. REMOVE STEERING KNUCKLE a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION 1. INSTALL STEERING KNUCKLE a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTICE: Be careful not to damage the oil seal and drive shaft boot. b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm (1,100 kgf-cm, 77 ft. lbs.) 2. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER a. Install the disc, brake caliper and 2 bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) b. Install the brake line clamp to the steering knuckle with bolt. Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.) 5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.) 6. 4WD: INSTALL DRIVE SHAFT LOCK NUT a. While applying the brakes, tighten the nut. Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.) b. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 9. DEPRESS BRAKE PEDAL SEVERAL TIMES 10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL Disassembly and Reassembly Page 4962 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE 2. INSTALL OIL SEAL a. Coat a new oil seal lip with power steering fluid. b. Using Special Service Tool (SST), press in the oil seal. SST 09950-60010 (09951-00330, 09951-00490, 09952-06010), 09950-70010 (09951-07360) NOTICE: ^ Make sure to install the oil seal facing in the correct direction. ^ Take care that the oil seal does not get reversed as you install it. 3. INSTALL STEERING RACK a. Install SST to the rack. SST 09631-20051 HINT: If necessary, scrape the burrs off the rack teeth end and burnish. b. Coat the SST with power steering fluid. c. Install the steering rack into the rack housing. NOTICE: Be careful not to damage the oil seal lip. d. Remove the SST SST 09631-20051 Page 2416 Page 5716 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 962 5. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3. Page 801 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Page 2683 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 8. REINSTALL INTAKE AIR CONNECTOR 9. REFILL WITH ENGINE COOLANT 10. REINSTALL THROTTLE BODY COVER Page 4203 11. 4WD: Remove oil seal (inside). A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration above). B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. Remove axle hub from steering knuckle. A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. SST P/N: 09710-28012-01 (09710-07031) SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. Remove bearing from steering knuckle. Page 917 10. CHECK CRANKSHAFT PULLEY POSITION Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No.1 timing belt cover. 11. INSTALL RH, LH CAMSHAFT TIMING PULLEYS a. Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the timing pulley. b. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 12. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY a. Remove any oil or water on the LH camshaft timing pulley, and keep it clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley. c. Turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and LH camshaft timing pulley. Page 61 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2244 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Paint - Iron Rust Contamination Repair Paint: Technical Service Bulletins Paint - Iron Rust Contamination Repair PAINT PA005-04 REVISED November 16, 2004 Title IRON PARTICLE RUST CONTAMINATION REPAIR Models '94 - Current Toyota & '04 - Current Scion TSB REVISION NOTICE: ^ December16, 2004: Text has been revised to more accurately describe cleaner (Auto Magic © Special Cleaner Concentrate is not an oxalic acid solution); Applicable Vehicles has been defined more clearly. The previous TSB should be discarded. Introduction The purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust. Applicable Vehicles ^ 1994 - Current model year Toyota vehicles. ^ 2004 - Current model year Scion vehicles. Condition During rail transportation or extended storage near industrial areas vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks train wheels exposure to heavy machinery facilities gnnding welding etc. Inspection This type of contamination can be identified by the presence of small red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as hood roof or deck lid. Caution: Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be affempted to repair the paint surface of an affected vehicle. This will result in further paint damage and detract from vehicle appearance. Repair Washing the affected paint surfaces with Auto Magic © Special Cleaner Concentrate is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. The correct usage of Auto Magic © Special Cleaner Concentrate is described in this bulletin. Warranty Information Required Tools & Materials General Precautions Ground Locations Clock: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 3129 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Page 4078 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. ^ 09023-00100 6. REMOVE BRAKE,CALIPER AND DISC Page 3450 Transmission Mode Indicator - A/T: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2001 CHART 27 Page 1311 Engine Oil Pressure: Testing and Inspection INSPECTION 1. 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: Use API SJ, Energy-Conserving or ILSAC multi-grade engine oil. SAE 5W-30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 2. CHECK ENGINE OIL LEVEL The oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and add oil up to the "F" mark. NOTICE: Do not fill with engine oil above the "F" mark. 3. REMOVE ENGINE UNDER COVER 4. REMOVE OIL PRESSURE SWITCH 5. INSTALL OIL PRESSURE GAUGE 6. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 7. CHECK OIL PRESSURE Oil pressure: 8. REMOVE OIL PRESSURE GAUGE 9. REINSTALL OIL PRESSURE SWITCH a. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Reinstall the oil pressure switch. 10. START ENGINE, AND CHECK FOR ENGINE OIL LEAKS Page 1870 Knock Sensor (Part 2) Page 419 Key Reminder Switch: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle 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 operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Locations Engine Room R/B Page 4116 ^ 09023-00100 6. REMOVE BRAKE CALIPER AND DISC A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. Page 121 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 2835 CHART 28 Page 6810 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 3567 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2947 Voltage: 4.2 - 4.8 V d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor. Page 4748 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1885 Page 5557 Seat Belt Reminder Buzzer: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Specifications Overdrive Assembly: Specifications O/D Support x Transmission Case 25 Nm Page 5902 Page 1157 Wheel Fastener: Service and Repair Rear REPLACEMENT 1. REMOVE REAR WHEEL 2. REMOVE BRAKE DRUM AND GASKET 3. REMOVE REAR HUB BOLT Using Special Service Tool (SST) and a brass bar or an equivalent, remove the hub bolt. SST 09650-17011 4. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a brass bar or an equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer. 5. INSTALL NEW GASKET AND BRAKE DRUM 6. INSTALL REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 405 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5970 Page 615 CHART 5 CHART 6 Component Locations Ignition Switch And Key Unlock Warning Switch Page 3239 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1312 11. REINSTALL ENGINE UNDER COVER Page 3404 Clutch: Specifications Forward Clutch Pack Clearance 0.4 - 0.8 mm Drum Bushing Inside Diameter 24.08 mm Sun Gear Input Drum and Direct Clutch Drum Distance 5.3 - 7.3 mm Flange Thickness No.61 3.0 mm No.60 3.2 mm No.45 3.4 mm No.62 3.6 mm No.44 3.8 mm No.42 4.0 mm No.63 4.2 mm No.64 4.4 mm 1st & Reverse Brake Piston Return Spring Standard Free Length 12.9 mm mm Pack Clearance 0.50 - 1.02 mm Flange Thickness No.50 5.0 mm No.51 4.8 mm No.52 4.6 mm No.53 4.4 mm No.54 4.2 mm No.55 4.0 mm Page 2826 CHART 23 Page 5638 a. Install the retractor of front seat outer belt. 1. Install the retractor of front seat outer belt with the 2 bolts. Torque: Upper bolt: 8.3 N.m (85 kgf.cm, 74 in.lbf) Lower bolt: 42 N.m (430 kgf.cm, 31 ft.lbf) 2. Connect the pretensioner connector as shown in the illustration. b. Install the quarter trim. 1. Install the quarter trim. 2. Install the front seat outer belt shoulder anchor with the bolt. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) 3. Install the cap. 4. Install the quarter trim belt hole cover. c. Install the front seat outer belt floor anchor with the bolt. d. Install the back panel upper garnish. Page 6408 Key Reminder Switch: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 1591 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: N-cap, 108 kPa Page 3951 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 4053 SST P/N: 09527-17011 B. Coat MP grease to the oil seal lip. 18. Install new dust cover and axle hub to steering knuckle. A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. SST P/N: 09649-17010 19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is installed completely. 20. 2WD: Install new lock nut. A. Using the following SST, install and torque a NEW lock nut to the axle hub. SST P/N: 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. Page 698 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 3568 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Steering/Suspension - Ball Joint Inspection Ball Joint: Technical Service Bulletins Steering/Suspension - Ball Joint Inspection PRODUCT GENERAL INFORMATION PG027-02 December 4, 2002 Title: SUSPENSION BALL JOINT INSPECTION Models: See Applicable Models Introduction This bulletin describes the inspection method and free play specification figures for suspension ball joints. The on-vehicle inspection methods have been standardized. Applicable Vehicles Warranty Information Page 5750 Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 6288 Audible Warning Device Control Module: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 3020 d. Connect the vacuum hose to intake air resonator. e. Connect the fuel return hose to the pressure regulator. 2. CHECK FOR FUEL LEAKS Page 6193 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 3425 Fluid - A/T: Service and Repair 1. Drain transaxle fluid, then install drain plug and new gasket. 2. With engine Off, add fluid through dipstick tube. Do not overfill. 3. Start engine, then move shift selector through all positions, ensuring smooth operation. 4. Allow to idle, then check at COOL level. 5. Allow to reach normal operating temperature, then recheck. Page 3459 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1935 CHART 26 Page 6164 Page 4499 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Instruments - Coolant Temperature Gauge Inaccurate Temperature Gauge: All Technical Service Bulletins Instruments - Coolant Temperature Gauge Inaccurate ELECTRICAL EL009-01 October 12, 2001 Title: TEMPERATURE GAUGE INACCURATE Models: '00 - '01 Tundra Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the engine coolant temperature gauge displays an abnormally high reading during normal engine operating temperatures. To address this condition, an updated Temperature Gauge has been made available. Applicable Vehicles ^ 2000 - 2001 model year Tundra trucks, built prior to the VIN shown. Production Change Information Parts Information Repair Procedure IMPORTANT: Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the temperature gauge. 1. Remove the four bolts securing the combination meter assembly. 2. Replace the Temperature Gauge. 3. Reassemble the combination meter. Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3569 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 6339 Clock: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 3211 Step 3 Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 696 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Page 1982 CHART 10 Page 1011 Fluid - Differential: Service and Repair Rear FILL DIFFERENTIAL WITH HYPOID GEAR OIL Page 5050 Page 5783 Trailer Connector: Testing and Inspection TRAILER TOWING T6 TRAILER SOCKET 2 - GROUND : Approx. 12 volts with light control SW at TAIL or HEAD position 1 - GROUND : Approx. 12 volts with ignition SW at ON position and shift level in R position 4 - GROUND : Always continuity Page 4376 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Page 1608 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 8. REINSTALL INTAKE AIR CONNECTOR 9. REFILL WITH ENGINE COOLANT 10. REINSTALL THROTTLE BODY COVER Page 6264 Glossary Of Terms And Symbols (Part 1) Page 4001 DISASSEMBLY 1. DISCONNECT CONNECTOR (a) Remove the screw and clamp from the ABS actuator. Torque: 2.9 Nm (30 kgf-cm, 26 inch lbs.) (b) Disconnect the connector. 2. REMOVE ABS ECU Using a hexagon wrench (4 mm), remove the 4 bolts and ABS ECU. Torque: 4.4 Nm (45 kgf-cm, 39 inch lbs.) NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing damage on the valve body. If the dirt and the like is stuck to the sealing surface, use plastic tools or soft objects to remove the dirt. Do not use chemical solvents. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 4246 Required SSTs Repair Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember with a foot PKB (on an automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click" and then press the PKB pedal a second time so it will disengage when it is released. At this time, the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step C, then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Proceed to the Repair Procedures that follow. F. If no vibration is felt during step C, then the front brake assemblies are the cause of brake vibration on this vehicle. Refer to TSB No. BR004-02, "Front Brake Vibration," for parts and repair information relating to Tundra front brake vibration. 3. Measure the rear axle shaft centering area diameter. If the measured value deviates from the standard (105.946 - 106 mm [4.171 - 4.173 in.]), replace the rear axle shaft (Standard: Refer to Figure 1). Page 4196 Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1869 Knock Sensor: Locations Knock Sensor (Part 1) Service and Repair Sun Gear: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair. Specifications Page 2543 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Page 5613 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 6497 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 154 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Page 554 CHART 10 Page 1691 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 4616 Engine Room R/B Fuse Applications (Part 2) Engine Room Fuse Details Page 119 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 1189 Connecting Rod Bearing: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 3685 3. 4WD: DISCONNECT DRIVE SHAFT a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut. 4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. REMOVE BRAKE CALIPER AND DISC a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake caliper and disc. NOTICE: Do not damage the brake tube. c. Support the brake caliper securely. 6. REMOVE SHOCK ABSORBER 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Page 4829 Replacement Requirements Airbag Sensor Assembly: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Diagram Information and Instructions Lamp Control Module: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6190 Splice Location B11 Page 3557 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 3242 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 1225 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER Remove the 9 bolts, seal washers and cylinder head cover. 7. REMOVE LH CYLINDER HEAD COVER a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal washers and cylinder head cover. 8. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360°) and align the mark. 9. INSPECT VALVE CLEARANCE Page 4932 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for no more than 5 - 10 seconds at a time. If the spark does not occur, do the test as per the given flow chart. 7. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) 8. Reinstall the ignition coils (with igniter). Page 1467 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Air conditioning switched OFF 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Page 5450 SRS Warning Light: Component Tests and General Diagnostics SRS WARNING LIGHT CHECK a. Turn the ignition switch to the ACC or ON position and check that the SRS warning light lights up. b. Check that the SRS warning light goes out after approx. 6 seconds. HINT: When the ignition switch is at ACC or ON and the SRS warning light remains on or flashes, the airbag sensor assembly has detected a malfunction code. - If, after approx. 6 seconds have elapsed, the SRS warning light sometimes lights up or the SRS warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit can be considered likely. Proceed to "SRS warning light circuit malfunction". Page 1077 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 5394 - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED a. Do a diagnostic system check. b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check the deformation on the horn button contact plate of the steering wheel. - Check the damage on the spiral cable connector and wire harness. HINT: If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. Page 6420 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 723 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Page 6493 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 3473 Transmission Mode Indicator - A/T: Description and Operation ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR SYSTEM OUTLINE The electronically controlled transmission electrically controls the, throttle pressure, lock-up pressure, and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls the gear shift timing and lock-up timing in response to the vehicle's driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection of the gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. GEAR SHIFT OPERATION When driving, the engine warm up condition is input as a control signal from the engine coolant temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA, VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. LOCK-UP OPERATION When the engine control module decides based on each signal that the lock-up condition has been met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the electronically controlled transmission solenoid to GROUND. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input to TERMINAL STP of the engine control module. As a result, the engine control module cuts the current to the solenoid to release the lock-up. 4. OVERDRIVE CIRCUIT - O/D main SW on When the O/D main SW is switched to ON position, a signal is input to TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range, through the control of the engine control module. - O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range through the control of the engine control module. When in the overdrive range already, shift down is made. Page 5790 Trailer Connector: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 2615 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Page 721 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Symptom Related Diagnostic Procedures Clock: Symptom Related Diagnostic Procedures Problem Symptoms Table CLOCK TROUBLESHOOTING HINT: Troubleshoot the clock according to the table. Troubleshooting No. 1 Step 1 Page 2470 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 5930 Page 2836 CHART 29 Page 216 Engine Control Module: Locations Instrument Panel Page 1325 3. REMOVE OIL COOLER a. Disconnect the 2 oil cooler hoses from the oil cooler. b. Remove the union bolt, plate washer and oil cooler. c. Remove the O-ring from the oil cooler. INSPECTION INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. INSTALLATION 1. INSTALL OIL COOLER a. Clean the oil cooler contact surface on the cooler mounting. b. Place a new O-ring to the oil cooler. c. Apply a light coat of engine oil on the threads and under the head of the union bolt. d. Install the oil cooler and plate washer with the union bolt. Torque: 68.6 Nm (700 kgf-cm, 51 ft. lbs.) e. Connect the 2 oil cooler hoses to the oil cooler. 2. INSTALL OIL FILTER 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR ENGINE OIL LEAKS 5. CHECK ENGINE OIL LEVEL Page 6290 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 120 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 4901 - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 2688 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Page 3405 Clutch: Specifications O/D Brake Piston Return Spring Standard Free Length 17.82 mm Piston Stroke 1.32 - 1.62 mm Flange Thickness No.77 3.3 mm No.78 3.5 mm No.79 3.6 mm No.80 3.7 mm No.81 3.8 mm No.82 3.9 mm None 4.0 mm Page 1961 Applicable Vehicles Page 5616 Seat Belt Reminder Lamp: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Page 3061 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Page 1651 Catalytic Converter: Testing and Inspection THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM ON-VEHICLE INSPECTION 1. CHECK EXHAUST PIPE ASSEMBLY a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or damage. 2. INSPECT TWC Check for dents or damage. If any part of protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT HEAT INSULATOR a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and heat insulator. Page 6719 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 646 Oxygen Sensor: Description and Operation Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Page 4734 Driver Side J/B And Integration Relay Fuse Applications (Part 1) Page 556 CHART 12 CHART 13 Page 3096 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 1092 Driver Side J/B And Integration Relay Page 6191 Cruise Control: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 1278 1. Remove the engine under cover. 2. Drain the engine coolant. 3. Remove the intake air connector assembly. 4. Remove the radiator fan shroud. 5. Remove the drive belt, fan, fluid coupling, and fan pulley. 6. Without disconnecting the power steering fluid lines, remove the power steering pump. HINT: Suspend the power steering pump securely. 7. Remove the drive belt idler pulley. 8. Remove the right hand (RH) No. 3 timing belt cover. 9. Remove the No.2 timing belt cover. 10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting bracket. HINT: Suspend the A/C compressor securely. 11. Disconnect the A/C compressor mounting bracket. Testing and Inspection Tail Lamp Relay: Testing and Inspection w/ Daytime running light: INSPECT TAILLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 948 A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the accessory drive belt tensioner to release tension and remove the accessory drive belt. HINT: The pulley bolt for the belt tensioner has a left hand thread. B. Using the accessory drive belt routing label located on the passenger side of the radiator core support as a guide, install the new accessory drive belt. 2. Check belt tensioner operation. A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force. B. Ensure proper alignment of the belt with the ribbed grooves of each pulley. C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each pulley. D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see illustration). E. If the arrow mark falls outside area "A," the drive belt is incorrect. HINT: When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect. Page 6406 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SRS AIRBAG PRECAUTION CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front passenger airbag and failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a 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 described. 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. 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.) Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one. Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the SRS is completed, check the SRS warning light check. 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 systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. If the vehicle is equipped with a mobile communication system, refer to the precaution. Page 3378 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 3232 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1024 4. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) b. Fill with fresh engine oil. Capacity: c. Reinstall the oil filler cap. HINT: Install the oil filler cap facing the direction as shown in the illustration. 5. START ENGINE AND CHECK FOR ENGINE OIL LEAKS 6. RECHECK ENGINE OIL LEVEL 7. w/Oil filter change: REINSTALL ENGINE UNDER COVER Page 4784 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 228 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4292 Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 485 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Page 6665 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the slide rheostat, then read the rheostat indication. If resistance value is not as specified, replace the engine coolant sender gauge. Page 2346 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4189 Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). ^ 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Page 5365 Air Bag Harness: Testing and Inspection INSPECTION HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. Check 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. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Codes See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 5059 Brakes - Front Brakes Vibrating Technical Service Bulletin # BR004R-02 Date: 040305 Brakes - Front Brakes Vibrating BRAKES BR004-02 REVISED September 16, 2002 Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra TSB REVISION NOTICE: ^ March 5, 2004: A torque specification in, step 24, was changed. ^ September 8, 2003: A torque specification in, step 28, was changed. The previous TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles ^ 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3145 Ignition Coil: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for no more than 5 - 10 seconds at a time. If the spark does not occur, do the test as per the given flow chart. 7. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) 8. Reinstall the ignition coils (with igniter). Specifications Camshaft Gear/Sprocket: Specifications Tightening Torque Crankshaft Pulley ................................................................................................................................ ...................................................................... 245 Nm LH, RH Camshaft Timing Pulleys ................... .......................................................................................................................................................... 108 Nm Page 6671 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 4789 Relay Box: Connector Views Engine Room R/B Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ............................................................................................................................................... ............................................................. 1.0L (1.1 Qt) Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 2005 CHART 30 Page 2864 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Testing and Inspection Seat Belt Buckle Switch: Testing and Inspection Bench Type and Passenger Side: INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. (w/o Bench Type (Driver Side): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 3 and 4 on the switch side connector with the switch ON (elt fastened). b. Check that no continuity exists between terminal 3 an 4 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. Separate Type (w/ Power Seat): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. Page 2181 Engine Coolant Temperature (ECT) Sensor Page 997 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 2372 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Page 2400 Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 542 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 4899 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Component Locations Audible Warning Device Control Module: Component Locations Instrument Panel Page 553 CHART 8 CHART 9 Page 1433 6. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY a. Loosen the 4 nuts holding the fluid coupling to the fan bracket. b. Remove the drive belt. c. Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley. 7. DISCONNECT PS PUMP Remove the 3 bolts, and disconnect the PS pump from the engine. HINT: Suspend the PS pump securely. 8. REMOVE DRIVE BELT IDLER PULLEY Remove the pulley bolt, cover plate and idler pulley. 9. REMOVE RH NO.3 TIMING BELT COVER Remove the 3 bolts, nut and RH No.3 timing belt cover. 10. REMOVE LH NO.3 TIMING BELT COVER a. Disconnect the engine wire from the 2 wire clamps. b. Remove the 4 bolts and nut. c. Disconnect the camshaft position sensor wire from the wire clamp on the LH No.3 timing belt cover. d. Disconnect the camshaft position sensor connector from the connector bracket. e. Disconnect the camshaft position sensor connector. f. Remove the wire grommet from the LH No.3 timing belt cover. g. Remove the LH No.3 timing belt cover. h. Remove the bolt, nut and oil cooler pipe Page 1745 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 2959 e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time. 4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away. 5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag. g. Observe these precautions when connecting the fuel tube connector (quick type): 1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe. Page 5061 Page 2262 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 4361 Required Tools & Material Page 2238 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 1694 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Page 2572 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair ON-VEHICLE REPAIR 1. 5VZ-FE: DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission. 2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 4. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR NOTICE: Be careful not to twist the wire harness. 6. CONNECT OIL COOLER PIPE a. Install the elbow to the transmission. Page 222 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2661 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Page 6020 INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2137 d. Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. e. Adjust the spark plug electrode gap. Electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) g. Reinstall the ignition coils (with igniter). Page 1438 1. 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 mount bolt of the camshaft timing pulley. If there is any defect, as shown in the illustration, check these points: a. Premature parting - Check for proper installation. - Check the timing cover gasket for 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 even 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 timing cover for damage and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. INSPECT IDLER PULLEYS a. Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. b. Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. INSPECT TIMING BELT TENSIONER a. Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. Axle Shaft, Conventional Fixed/Floating Page 484 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Testing and Inspection Power Window Switch: Testing and Inspection Driver's Switch Passenger's Switch : Window Unlock Passenger's Switch : Window Lock INSPECT POWER WINDOW MASTER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 207 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6085 Paint: Technical Service Bulletins Paint - Refinishing Information COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: TOPCOAT SAND & POLISH SECTION: REFINISH BULLETIN # 173 MODELS: ALL TOYOTA LEXUS AND SCION DATE: APRIL 2009 Customers have high expectations for automotive paint finish appearance and expect repairs to match factory color gloss and texture. Flawed refinish appearance is a cause of concern and will likely have a negative affect on customer satisfaction and retention. Toyota recognizes the reality of paint finish application in the shop environment. In addition to color matching and blending countermeasures to remove paint process intrusion (dirt nibs) are necessary to achieve an undetectable finish match. This is also common in manufacturing plants when process intrusion is encountered. Countermeasures are defined as; ultra-fine sanding to level nibs followed by polishing to a level of gloss and texture consistent with the original finish. Technicians undertaking these tasks should review applicable technical data sheets for product process and handling instructions as well as applicable safety information. Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and Lexus L101 Paint Finish Repair training. Please visit for scheduling and registration information. Page 6142 * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type: Power Adjuster) section of the applicable service manual. 2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the location shown below. 3. Reassemble the front seat with the new seat cushion cover. NOTE: Do not use air tools when installing the seat assembly back into the vehicle. Locations Fuse: Locations Driver Side J/B And Integration Relay Page 1545 1. Turn the temperature control knob to the full cold position. 2. Inspect the clearance between the water control valve lever and the lever stop. If the lever does not contact the lever stop, proceed to step 3. 3. If the lever does not contact the lever stop: A. Disengage the cable retaining clip. B. Pull up on the cable sheath until the water control valve lever contacts the lever stop. C. Re-fasten the cable retaining clip. Locations Intake Air Temperature Sensor: Locations Mass Air Flow (MAF) Meter The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 6556 Glossary Of Terms And Symbols (Part 1) Page 576 CHART 29 Page 2506 CHART 30 Page 3304 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 4062 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Page 3349 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 3547 Transmission Cooler: Service and Repair REMOVAL Page 5234 Heater Control Assembly Page 2156 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals with the switch ON (switch pin released). b. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Locations Hose/Line HVAC: Locations Refrigerant Line (Part 1) Page 6596 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 91 Glossary Of Terms And Symbols (Part 1) Page 5813 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 371 Oil Pressure Sender: Testing and Inspection INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi). If operation is not as specified, replace the switch. 5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a. Disconnect the connector from the sender gauge. b. Check that no continuity exists between the terminal and ground with the engine stopped. c. Check that continuity exists between the terminal and ground with the engine running. HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi). If the continuity is not as specified, replace the sender gauge. Page 6200 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1675 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 5996 a. Remove the bolt and front seat outer belt floor anchor. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) b. Using a screwdriver, remove the cap. c. Remove the bolt and front seat outer belt shoulder anchor. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) d. Employ the same manner described above to the other side. 8. Access cab: REMOVE ROOF SIDE RAIL GARNISH a. Using a screwdriver, remove the caps. b. Using a torx driver, remove the 2 torx screws and assist grip. c. Using a screwdriver, remove the roof side rail garnish. 9. REMOVE SUN VISORS a. Remove the 4 screws and 2 sun visors. b. w/ Light: Disconnect the connector. 10. REMOVE SUB-VISORS Remove the 4 screws and 2 sub-visors. 11. REMOVE FRONT PERSONAL LIGHT Page 4772 Engine Compartment Instrument Panel Locations Page 2505 CHART 29 Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Page 996 Fluid - A/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ................................................. ATF Dexron II or III Collision / Non-Collision Inspections Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 3311 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 2085 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Page 4624 Engine Compartment Instrument Panel Locations Testing and Inspection Wiper Motor: Testing and Inspection Low Speed: INSPECT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor operates at low speed. If operation is not as specified, replace the motor. High Speed: INSPECT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor operates at high speed. If operation is not as specified, replace the motor. Stopping at Stop Position: INSPECT WIPER MOTOR OPERATION a. Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 5. Page 4977 Steering Wheel: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. Page 6423 Glossary Of Terms And Symbols (Part 1) Page 3137 Crankshaft Position Sensor Page 2206 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 6548 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 2288 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Specifications Fuel Tank And Line Page 4329 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Page 4561 Antenna - Loose Mast Antenna Mast: All Technical Service Bulletins Antenna - Loose Mast AUDIO AU002-01 June 1, 2001 Title: ANTENNA MAST DURABILITY Models: '00 - '01 Tundra Introduction Some customers may experience a loose Tundra antenna mast due to the breakage of the antenna holder. A revised antenna holder assembly is available to resolve this issue. Applicable Vehicles ^ 2000 - 2001 model year Tundra vehicles. Production Change Information Parts Information Repair Procedure Replace antenna holder assembly. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 6079 SEQUOIA 5R5 (Overfender. Bumper. Running Board) SIENNA XLE (Cladding) LANDCRUISER (Bumper Colors) RAV4 "L" PACKAGE (P-Molding) 4RUNNER SR5 (Over Fender) Page 5078 II. Identification of Affected Vehicles Description and Operation Braking Sensor/Switch: Description and Operation Stop Light Switch This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. Page 2067 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 4217 Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. ^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). Page 2673 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Page 4118 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. Page 4334 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. ^ 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. ^ 09710-28012-01 (09710-07031) ^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 6963 Back Window Glass: Service and Repair REMOVAL HINT: For step 2 to 10, refer to Headliner. 1. Access cab: REMOVE REAR SEAT 2. Standard cab: REMOVE FRONT DOOR SCUFF PLATES 3. Access cab: REMOVE ACCESS DOOR SCUFF PLATES 4. REMOVE ASSIST GRIPS 5. Standard cab: REMOVE FRONT PILLAR GARNISHES 6. Access cab: REMOVE ROOF SIDE RAIL GARNISHES 7. REMOVE ROOM LIGHT 8. Standard cab: REMOVE COAT HOOK 9. Standard cab: REMOVE BACK PANEL UPPER GARNISH 10. REMOVE QUARTER TRIMS 11. REMOVE REAR PART OF ROOF HEADLINING a. Standard cab: Remove the 2 clips and rear part of the roof headlining. b. Access cab: Remove the 3 clips and rear part of the roof headlining. 12. REMOVE BACK WINDOW GLASS a. Remove the 4 nuts. b. Using a screwdriver, loosen the weatherstrip from the body. NOTE: Be careful not to damage the body paint. HINT: Tape the screwdriver tip before use. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * 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 systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Testing and Inspection Page 3647 Seals and Gaskets: Service and Repair Rear Differential REPLACEMENT 1. DRAIN DIFFERENTIAL OIL 2. DISCONNECT REAR PROPELLER SHAFT 2WD: See Propeller Shaft; Service and Repair. 4WD: See Propeller Shaft; Service and Repair. 3. REMOVE COMPANION FLANGE a. Using a chisel and hammer, loosen the staked part of the nut. b. Using Special Service Tool (SST) to hold the flange, remove the nut. SST 09330-00021 c. Using SST, remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050) Page 4093 Required SSTs Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. Page 3026 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 3872 5. INSPECT ACTUATOR OPERATION a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD -> 4HI position. b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 2WD position. Ground Locations Radio/Stereo: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Specifications Axle Nut: Specifications Front Drive Shaft Lock Nut 235 Nm (173 ft.lb) Page 3314 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 2806 Page 67 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2587 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 5251 Control Assembly: Service and Repair Air Conditioning / Heater Control Assembly Removal and Installation Air Conditioning Control Assembly (Center Cluster Integration) REMOVAL Page 4780 Glossary Of Terms And Symbols (Part 1) Page 5751 Perform the procedure shown if there is any lamp malfunction. Page 5775 Trailer Connector: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6411 Splice Location B11 Page 915 b. Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing downward. c. Measure the protrusion of the push rod from the housing end. Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 inch) If the protrusion is not as specified, replace the tensioner. 4. INSPECT WATER PUMP INSTALLATION 1. INSTALL CRANKSHAFT TIMING PULLEY a. Align the timing pulley set key with the key groove of the pulley. b. Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-46011 2. INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY a. Apply adhesive 2 or 3 threads of the pivot bolt. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using a 10 mm hexagon wrench, install the plate washer and No.1 idler pulley with the pivot bolt. Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the No.2 idler pulley with the bolt. Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.) d. Check that the No.1 and No.2 idler pulleys moves smoothly. Page 3128 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. Page 2921 Catalytic Converter: Testing and Inspection THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM ON-VEHICLE INSPECTION 1. CHECK EXHAUST PIPE ASSEMBLY a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or damage. 2. INSPECT TWC Check for dents or damage. If any part of protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT HEAT INSULATOR a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and heat insulator. Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 4679 Engine Room R/B Details Page 1633 1. PLACE THERMOSTAT IN WATER INLET HOUSING a. Install a new gasket to the thermostat. b. Insert the thermostat into the water inlet housing with the jiggle valve facing straight upward. HINT: The jiggle valve may be set within 30° of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.) 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR COOLANT LEAKS 5. RECHECK ENGINE COOLANT LEVEL Page 6676 Glossary Of Terms And Symbols (Part 2) Page 6201 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 5700 Wireless Transmitter Identification Fuel Pump Relay Fuel Pump Relay: Testing and Inspection Fuel Pump Relay INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP) 3. INSPECT FUEL PUMP RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 4. INSPECT FUEL PUMP RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. 5. REINSTALL FUEL PUMP RELAY 6. REINSTALL RELAY BOX COVER Page 4379 A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. 8. DISCONNECT LOWER BALL JOINT Page 3212 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 3335 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 1427 Timing Belt: Diagrams TIMING BELT REPLACEMENT W/ RELATED COMPONENTS Part 1 of 4 Page 3915 Transmission Mode Indicator - A/T: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1) Page 5802 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 1048 3. BLEED BRAKE LINE (a) Connect the vinyl tube to the caliper. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. SST 09751-36011 (c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (d) Repeat (b) and (c) until all the air in the fluid has been bled out. Torque: (Bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.) (e) Repeat the procedure on the previous page to bleed the air out of brake line for each wheel. 4. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 LOAD SENSING PROPORTIONING AND BY-PASS VALVE ON-VEHICLE INSPECTION 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab: 5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.) 2. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi) Page 3422 Fluid - A/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ................................................. ATF Dexron II or III Page 4554 b. Install the terminal insulator with the nut. Torque: 4.1 N.m (41.5 kgf.cm, 36 in.lbf) 8. CHECK THAT ROTOR ROTATES SMOOTHLY REPLACEMENT 1. REPLACE FRONT BEARING a. Remove the 4 screws and bearing retainer. b. Using SST and a press, press out the bearing. SST 09950-60010 (09951-00260, 09952-06010) c. Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00520) d. Install the bearing retainer with the 4 screws. Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf) 2. REPLACE REAR BEARING Page 3496 7. INSTALL PARKING LOCK PAWL BRACKET Install the parking lock pawl bracket with the 3 bolts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) HINT: Push the lock rod fully forward. - Check that the parking lock pawl operates smoothly. 8. INSTALL VALVE BODY Testing and Inspection Hazard Warning Switch: Testing and Inspection INSPECT HAZARD WARNING SWITCH CONTINUITY a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster integration. c. Check that continuity exists between terminal 17 and terminal 1 with the switch ON. d. Check that no continuity exists between terminal 17 and terminal 1 with the switch OFF. If continuity is not as specified, replace the switch. Page 2608 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 1846 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications New gasket and the ECT sensor. Torque: .......................................................................................... .................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf) New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ............................................... .................................................................................................................................. 18 N.m (185 kgf.cm, 13 ft.lbf) Page 2998 Injector (Part 2) Front fuel pipe with the bolt, 4 new gaskets and 2 union bolts. Torque:..............39 N.m (400 kgf.cm, 29 ft.lbf) for union bolts Torque:..............7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt Bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Torque:..............7.5 N.m (80 kgf.cm, 66 in.lbf) Page 4362 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Testing and Inspection Power Seat Switch: Testing and Inspection Slide Switch Front Tilt Switch Rear Lifter Switch Reclining Switch INSPECT POWER SEAT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4722 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4147 3. REMOVE CALIPER Remove the 2 mounting bolts and caliper. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) 4. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 5. REMOVE 2 PADS AND 4 ANTI-SQUEAL SHIMS NOTICE: The anti-rattle spring and clip can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill brake reservoir with brake fluid and bleed brake system. - Check for leaks. Page 6090 Paint: Application and ID Page 5951 Page 2043 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 5173 3. 4WD: DISCONNECT DRIVE SHAFT a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut. 4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. REMOVE BRAKE CALIPER AND DISC a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake caliper and disc. NOTICE: Do not damage the brake tube. c. Support the brake caliper securely. 6. REMOVE SHOCK ABSORBER 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Electrical Specifications Resistance Electrical Specifications Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 6358 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 1372 Intake Manifold: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 5058 Page 3591 Vehicle Speed Sensor NO.2 Diagram Information and Instructions Transmission Mode Indicator - A/T: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 3897 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 1955 Engine Bank Identification Heater Control Assembly Control Assembly: Service and Repair Heater Control Assembly Removal and Installation Heater Control Assembly REMOVAL Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill With Manual Transmission 10.6 qt (US) With Automatic Transmission 12.3 qt (US) Locations Fuse Block: Locations Driver Side J/B And Integration Relay Page 5788 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 960 e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time. 4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away. 5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag. g. Observe these precautions when connecting the fuel tube connector (quick type): 1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe. Page 201 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 3323 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Page 217 Engine Control Module (ECM) Page 598 Page 2044 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 6407 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 4922 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5965 Page 2765 CHART 21 Page 4121 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: Page 1359 Oil Pressure Sender: Testing and Inspection INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi). If operation is not as specified, replace the switch. 5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a. Disconnect the connector from the sender gauge. b. Check that no continuity exists between the terminal and ground with the engine stopped. c. Check that continuity exists between the terminal and ground with the engine running. HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi). If the continuity is not as specified, replace the sender gauge. Page 6553 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 5112 Page 4302 21. 4WD: Using the following SSTs and a press, install the bearing spacer. SST P/N: 09950-60010 (09951-00650) SST P/N: 09950-70010 (09951-07150) 22. 4WD: Install new oil seal (inside). A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). SST P/N: 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. Install steering knuckle. A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. Connect the lower ball joint to the steering knuckle with 4 bolts. Page 6736 Brake Lamp: Component Tests and General Diagnostics INSPECTION 1. w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. w/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. INSPECT HI-MOUNTED STOP LIGHT ASSEMBLY CONTINUITY Using the ohmmeter, check that continuity exists between terminal 1 and terminal 2. If continuity is not as specified, replace the light assembly or bulb. Page 1594 Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 108 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01) 6. When using the radiator cap tester, tilt it more than 30 degrees. Page 3112 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Page 1827 Mass Air Flow (MAF) Meter Page 3009 Injector (Part 2) REMOVAL 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR Page 2641 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4955 4. REMOVE RIGHT-HAND AND LEFT-HAND CLIPS, RACK BOOTS AND CLAMPS a. Using a screwdriver, loosen the 2 clamps. b. Remove the 2 clips and boots. HINT: Mark the Right-Hand and Left-Hand boots. NOTICE: Be careful not to damage the boot. 5. REMOVE RIGHT-HAND AND LEFT-HAND RACK ENDS AND CLAW WASHERS a. Using a screwdriver and hammer, unstake the washer. NOTICE: Avoid any impact on the steering rack. b. Using a spanner to hold the steering rack steadily, and using SST, remove the rack end. SST 09922-10010 HINT: Mark the Right-Hand and Left-Hand rack ends. NOTICE: Use SST 09922-10010 in the direction shown in the illustration. c. Remove the washer from the rack end. d. Employ the same manner described to the other side. Page 3795 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 4314 Required Tools & Material Page 1760 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 4412 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection NOTE: This article contains corrected data processed from TSB# PG001-05. ABS ACTUATOR ON-VEHICLE INSPECTION 1. CONNECT TOYOTA HAND-HELD TESTER a. Connect the TOYOTA hand-held tester to the DLC3. b. Start the engine and run it at idle. c. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. HINT: Please refer to the TOYOTA hand-held tester operator's manual for further details. 2. INSPECT ABS ACTUATOR MOTOR OPERATION a. Check that the operation sound of the ABS actuator motor can be heard when the motor relay is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. If the operation sound cannot be heard, replace the ABS actuator because the motor operation is in failure. b. Turn the motor relay OFF. 3. INSPECT RIGHT FRONT WHEEL SOLENOID a. Depress the brake pedal and hold it for about 15 seconds, and check that the brake pedal does not go down further. If the brake pedal goes down, replace the ABS actuator because the sealing condition of the reduction solenoid valve is abnormal. b. Check that the brake pedal does not pulsate when the motor relay is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. If there is a pulsation in the brake pedal, replace the ABS actuator because the sealing condition of the reduction solenoid valve is abnormal. c. Turn the motor relay OFF. d. Depress the brake pedal and hold it until the step (g) is completed. e. Check that the brake pedal does not go down further when the SFRH solenoid is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep solenoid ON for more than 2 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. If the brake pedal goes down, replace the ABS actuator because the holding solenoid valve operation is abnormal. HINT: To prevent the solenoids, TOYOTA hand-held tester turns OFF automatically 2 secs. after has been turned ON simultaneously. f. Check that the brake pedal goes down further when the SFRR solenoid is turned ON by the TOYOTA hand-held tester. If the brake pedal does not go down, replace the ABS actuator because the reduction solenoid valve operation is abnormal. g. Check that the brake pedal returns when the motor relay is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than Specifications Piston Ring: Specifications Ring Groove Clearance No.1 .............................................................................................................. ............................................................................................. 0.030 - 0.080 mm No.2 .......................... .............................................................................................................................................................. ................... 0.030 - 0.070 mm Standard End Gap No.1 ...................................................................................................................... ..................................................................................... 0.300 - 0.400 mm No.2 .................................. .............................................................................................................................................................. ........... 0.400 - 0.550 mm Oil (side rail) ............................................................................................... ............................................................................................... 0.130 - 0.380 mm Maximum End Gap No.1 ..................................................................................................................... ..................................................................................................... 1.10 mm No.2 ................................ .............................................................................................................................................................. ............................ 1.20 mm Oil (side rail) ............................................................................................ ................................................................................................................ 1.15 mm Page 2040 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3173 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Page 186 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 1906 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 267 Supplemental Restraint System Page 6132 * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type: Power Adjuster) section of the applicable service manual. 2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the location shown below. 3. Reassemble the front seat with the new seat cushion cover. NOTE: Do not use air tools when installing the seat assembly back into the vehicle. Locations Page 397 Splice Location B11 Page 5370 Airbag Sensor Assembly Page 5635 1. Disconnect the pretensioner connector as shown in the illustration. CAUTION: When removing the seat belt pretensioner, 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. 2. Remove the 2 bolts and retractor of front seat outer belt. 2. Access cab: REMOVE FRONT SEAT OUTER BELT a. Remove the 4 screws and front door scuff plate. b. Remove the 3 screws and rear door scuff plate. c. Remove the bolt and front seat outer belt floor anchor. d. Remove the front seat outer belt shoulder anchor. 1. Using a screwdriver, remove the cap. HINT: Tape the screwdriver tip before use. 2. Remove the bolt and front seat outer belt shoulder anchor. e. Remove the roof side rail garnish. 1. Using a screwdriver, remove the caps. HINT: Tape the screwdriver tip before use. 2. Using a torx driver, remove the 2 torx screws and assist grip. Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool) Page 114 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 702 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 2147 Intake: N = T + (A - 0.20 mm (0.008 inch)) Page 5285 Heater Control Valve: Testing and Inspection WATER VALVE ON-VEHICLE INSPECTION 1. WARM UP ENGINE 2. DISCONNECT WATER VALVE CONTROL CABLE 3. INSPECT WATER VALVE OPERATION a. Check that warm air blown out the vent when the water valve lever is moved to "WARM" position. b. Check that cool air blown out when the water valve is moved to the "COOL" position. If operation is not as specified, replace the water valve. 4. CONNECT WATER VALVE CONTROL CABLE Page 175 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 4927 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2172 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. A/T - Fluid Requirements Fluid - A/T: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 5113 Page 6499 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 4841 Wheel turning angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-in and wheel angle within the specified value. At this time, make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less Page 755 1. LH: REMOVE FRONT AIRBAG SENSOR a. 2UZ-FE: Remove the battery carrier, battery and battery tray. b. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with sensor assembly installed. c. Remove the 2 bolts and front airbag sensor. 2. RH: REMOVE FRONT AIRBAG SENSOR a. Remove the air cleaner assembly. b. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with sensor assembly installed. c. Remove the 2 bolts and front airbag sensor. INSTALLATION INSTALL FRONT AIRBAG SENSORS Page 4848 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 6663 Splice Location B11 Page 2706 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Page 1762 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Page 1140 3. 4WD: DISCONNECT DRIVE SHAFT a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut. 4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. REMOVE BRAKE CALIPER AND DISC a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake caliper and disc. NOTICE: Do not damage the brake tube. c. Support the brake caliper securely. 6. REMOVE SHOCK ABSORBER 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Page 5792 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 5903 Page 2336 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 6831 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 6197 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 6209 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3294 6. INSPECT LIMIT SWITCH CONTINUITY a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the transfer shift lever and after checking the operating sound, disconnect the connector and inspect the continuity between each terminal. HINT: When shifting the actuator fork shaft, connect the connectors. 7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check the combination meter. 9. INSPECT 4WD CONTROL ECU Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side connector from the back side. Page 1931 Page 127 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 645 Heated Oxygen Sensor Removal and Installation Blower Motor: Service and Repair Removal and Installation Blower Unit REMOVAL 1. REMOVE COOLING UNIT 2. REMOVE BLOWER UNIT a. Disconnect the connector from the blower motor. b. Disconnect the air inlet damper control cable from the blower unit. HINT: At the time of installation, please refer to the following item. Page 967 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 5476 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTE: Page 5215 Compressor And Magnetic Clutch (Part 2) Page 2680 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 6267 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3659 4. REMOVE DRIVE SHAFT LOCK NUT a. Using a screwdriver and hammer, remove the grease cap. b. Remove the cotter pin and lock cap. c. While applying the brakes, remove the lock nut. 5. DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT a. Remove the cotter pin and nut. b. Using Special Service Tool (SST), disconnect the lower suspension arm from the lower ball joint. SST 09628-62011 6. DISCONNECT DRIVE SHAFT FROM STEERING KNUCKLE a. Using a plastic hammer, disengage the drive shaft from the axle hub. b. Push the steering knuckle outward and disconnect the drive shaft from the steering knuckle. NOTICE: Be careful not to damage the oil seal, boots and dust seal. 7. Left-Hand drive shaft: REMOVE LEFT-HAND SHOCK ABSORBER Page 4080 Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. ^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). Page 3306 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 1580 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT RADIATOR RESERVOIR HOSE FROM RADIATOR 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. DISCONNECT LOWER RADIATOR HOSE FROM RADIATOR 6. DISCONNECT A/T OIL COOLER HOSES FROM RADIATOR 7. REMOVE NO.2 FAN SHROUD Remove the 2 clips and No.2 fan shroud. Page 2420 CHART 1 Page 6491 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 5250 3. REMOVE DEF. MODE SWITCH Release the 2 claws, then remove the switch. HINT: Tape the screwdriver tip before use. REASSEMBLY 1. INSTALL DEF. MODE SWITCH Install the switch. HINT: After installation, check the fitting 2 claws. 2. INSTALL BLOWER SPEED CONTROL SWITCH a. Install the switch with the 2 screws. b. Connect the connector. 3. INSTALL HEATER CONTROL CABLES Install the heater control cables to the heater control assembly. Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 2088 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Page 907 Page 2281 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Page 6604 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3047 Fuel Tank And Line Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation Page 103 Driver Side J/B And Integration Relay Inner Circuit Page 622 CHART 15 Page 4907 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 508 Step 1 Page 6835 Lamp Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 5872 a. Tie both piano wire ends to wooden blocks or similar objects. b. Cut the adhesive tape by pulling the piano wire as shown in the illustration. NOTE: If reusing the moulding, take care not to damage the moulding. - Do not damage the body. c. Remove the moulding. INSTALLATION 1. CLEAN BODY MOUNTING SURFACE a. Using a heat light, heat the body mounting surface to 40 - 60 °C (104 - 140 °F). NOTE: Do not heat the body excessively. b. Remove the adhesive tape from the body. c. Wipe off stains with cleaner. Page 1177 Camshaft Gear/Sprocket: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 3571 Glossary Of Terms And Symbols (Part 2) Page 4937 Key Reminder Switch: Component Tests and General Diagnostics INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key unlock warning system: INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer sounds. Page 2422 CHART 5 CHART 6 Page 2313 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 4519 The battery is now being tested. The progress bar fills in across the screen while testing. 12. Read or print the battery test results (press the PRINT soft key to print). Battery Inspection Results Once the test completes, proceed with one of the 5 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: "GOOD BATTERY" Return the battery to service. 2. Battery Condition: "GOOD-RECHARGE" Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and return it to service. 3. Battery Condition: "CHARGE & RETEST" Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and retest. NOTE: Failure to fully charge the battery before retesting may cause false readings. 4. Battery Condition: "REPLACE BATTERY" Replace the battery. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out-of-vehicle test before replacing it. 5. Battery Condition: "BAD CELL-REPLACE" Replace the battery. The decision indicates a bad cell within the battery. CAUTION: ^ If "FROZEN BATTERY" is displayed as the test result, allow the battery to reach a temperature of 40°F (4°C) before retesting. ^ NEVER CHARGE A FROZEN BATTERY GASES MAY FORM, CRACKING THE CASE AND CAUSING BATTERY ACID TO LEAK. Page 5796 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 276 2. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the airbag sensor assembly connectors. NOTE: Disconnect the connectors with the sensor assembly installed. b. Using a torx wrench, remove the 4 screws. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) c. Remove the airbag sensor assembly. INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. - Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. - Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with 4 screws. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) b. Connect the airbag sensor connectors. NOTE: Connection of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed with the specified torque. - If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. - When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installing , shake the sensor assembly to check that there is no looseness. 2. INSTALL LOWER CENTER COVER Page 3008 Fuel Injector: Service and Repair Injector (Part 1) Page 1068 Driver Side J/B And Integration Relay Fuse Applications (Part 2) Driver Side J/B And Integration Relay Fuse Applications (Part 3) Page 5081 Page 640 CHART 29 Body - Bumper Component Repair Rear Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: BUMPER COMPONENT REPAIR SECTION: EXTERIOR BULLETIN # 172 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2009 While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinforcements there is no way to certify that a repaired part will function as originally intended under all future operating conditions and subsequent collisions. Original Equipment bumper components comply with Federal Motor Vehicle Safety Standards established under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is recommended to replace damaged bumper impact energy absorbers and reinforcements with genuine new original equipment replacement parts only. For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair & Refinish Training. Visit www.crrtraining.com for training information. Page 1107 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4056 32. Depress brake pedal several times. 33. Fill the brake reservoir with brake fluid and bleed brake system. 34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check). Repair Procedure No. 2 1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits. NOTE: It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. 2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on the rotor), replace the rotors using the service parts from the Parts Information table. 3. Check any new disc rotor for runout. 4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure. 5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts Information table. 6. Perform a road test. Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the slide rheostat, then read the rheostat indication. If resistance value is not as specified, replace the engine coolant sender gauge. Page 3742 Splice Location B11 Removal and Installation Throttle Body: Service and Repair Removal and Installation Throttle Body (Part 1) Page 413 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2768 CHART 23 Page 1472 2. Tighten the union bolt by hand. 3. Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. Testing and Inspection Power Seat Motor: Testing and Inspection INSPECT SLIDE MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the seat adjuster. INSPECT SLIDE MOTOR PTC THERMISTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the ammeter to terminal 1 and the negative (-) lead to the battery negative (-) terminal, then move the seat cushion to the rear position. b. Continue to apply voltage, check that current changes to less than 1 ampere within 4 to 90 seconds. c. Disconnect the leads from terminals. d. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the seat cushion begins to move forward. If operation is not as specified, replace the seat adjuster Page 4987 - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. a. Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700 1. Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. 2. Check functioning of the SST. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the Page 2566 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 3333 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Page 2738 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Page 1067 Driver Side J/B And Integration Relay Fuse Applications (Part 1) Page 2574 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 4667 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4854 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 6492 Audible Warning Device Control Module: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 483 Engine Coolant Temperature (ECT) Sensor Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Torque ............................................................................................................. .................................................... 245 Nm (181 ft.lb) Wheels/Tires - Spare Tire Carrier Operation Information Spare Tire Carrier: Technical Service Bulletins Wheels/Tires - Spare Tire Carrier Operation Information PRODUCT GENERAL INFORMATION PG005-03 REVISED Title: SPARE TIRE CARRIER OPERATION Models: '91 - '08 Land Cruiser, '96 - '08 4Runner & Tacoma, '98 - '08 Sienna, '00 - '08 Tundra, '01 '08 Sequoia August 19, 2003 TSB REVISION NOTICE: ^ October 4, 2007: 2007 - 2008 model years have been added to Applicable Vehicles. ^ September 27, 2005: 2005 - 2006 model years have been added to Applicable Vehicles. The previous TSB should be discarded. Introduction The spare tire carrier may become damaged if an impact wrench or any other type of power tool is used to raise or lower the spare tire. The Owner's Manual, as well as a label near the drive nut, warns against the usage of an impact wrench or other power tools. Applicable Vehicles ^ 1991 - 2008 model year Land Cruiser vehicles. ^ 1996 - 2008 model year 4Runner and Tacoma vehicles. ^ 1998 - 2008 model year Sienna vehicles. ^ 2000 - 2008 model year Tundra vehicles. ^ 2001 - 2008 model year Sequoia vehicles. Operation Procedure Refer to the vehicle's Owner's Manual for vehicle specific instructions. 1. Locate the drive nut for the spare tire carrier. Refer to the vehicle's Owner's Manual for specific location. 2. Using the hub nut box wrench from the vehicle's tire tools kit, lower the spare tire to the ground. 3. Remove the tire from the carrier. 4. Installation of the spare tire is the reverse of removal. Warranty Information Page 6082 Parking and Paint Protection ^ Storage areas should be paved, well lit and secure. If your off-site storage lot is not paved, spread gravel down to minimize mud and dust. Be sure vehicles are driven carefully when moving them to or from a long-term lot. This will help minimize damage to the paint finish from road grit or gravel. ^ Park vehicles from right to left at least three feet apart. Leave enough space front and rear to easily walk between rows. ^ HVAC vent controls should be set to "Recirc" to minimize dust and odor intrusion. ^ Make sure the plastic door edge protectors are in place and fold in the side view mirror (if applicable). ^ Anti-rust covers or anti-rust film should remain on vehicle during storage 1. Anti-Rust Covers (behind wheel) should be removed at PDS. 2. Anti-Rust Film (applied to wheel) should be removed just prior to customer delivery. ^ Wash vehicles frequently. Battery ^ Turn off all electrical accessories, make sure windows and sunroof are closed and check that the transmission is in "park" (first or reverse for manual transmission vehicles). Do not apply the parking brake. ^ Test batteries monthly (more often in high heat or cold areas), using the Digital Battery System ^ Analyzer (P/N 00002-V8150-KIT). Refer to TSB PG001-06, "Battery Maintenance for In Stock Vehicles and Pre-Delivery" for complete battery maintenance procedures. ^ To reduce battery drain during long-term storage, remove the battery ground (-) cable of each vehicle and reinstall just before delivery to the customer. Locate the current PDS TSB on TIS for complete details. ^ If a hybrid vehicle is put into storage, the state of charge (SOC) of it's battery and auxiliary battery will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage, proper maintenance is necessary. Refer to TSB "Maintenance for HV & Auxiliary Batteries" for procedure and additional information. Tire Inflation Pressure If the vehicle is parked for long periods without being moved, a flat spot may develop on each tire surface in contact with the ground, even if the tires are inflated to specification. Tire inflation pressure should be checked once a month. Tire inflation pressure for storage only: 45 psi. Parts Rust If the vehicles in your storage area are exposed to a sea breeze and/or a significant precipitation corrosion with rust in some parts may occur. If rust is found remove it and treat it by applying rust inhibitor to prevent recurrence. Engine Starting and Vehicle Movement If the vehicle is stored over an extended period of time starting and running the engine periodically will ensure smooth running operation. 1. Start and operate the engine at an engine speed under 1,500 RPM for 15 minutes or longer. This also eliminates moisture in the exhaust system. NOTE Be sure to allow sufficient clearance at the rear of the vehicle to prevent other vehicles stored behind from getting damaged by exhaust gas. 2. Move the vehicle at least 30 feet to lubricate the transmission and differential and prevent tire flat-spot damage. 3. Raise engine speed above 3,000 RPM 10 times to eliminate moisture from the exhaust. A/C Compressor Lubrication To minimize the possibility of damage to the A/C compressor while storing a vehicle perform the following recommended maintenance procedures at Page 5624 - Check for cuts and minute cracks in wire harness or marked discoloration on the front seat outer belt. CAUTION: For removal and installation of the front seat outer belt,. Be sure to follow the correct procedure. 2. PRETENSIONER IS ACTIVATED a. Perform a diagnostic system check. b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Standard cab: Check for deformation of the quarter panel. - Access cab: Check for deformation of the ELR bracket. - Check for damage on the connector and wire harness. Page 624 CHART 18 CHART 19 Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection 5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire harness side connector. Page 1928 CHART 22 Page 897 Intake: N = T + (A - 0.20 mm (0.008 inch)) Page 348 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications New gasket and the ECT sensor. Torque: .......................................................................................... .................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf) New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ............................................... .................................................................................................................................. 18 N.m (185 kgf.cm, 13 ft.lbf) Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Gauge: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1116 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 6359 Clock Page 6338 Splice Location B11 Page 3451 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 3794 Step 3 Page 1171 8. Push in the camshaft oil seal. 9. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). 10. Install the oil feed pipe the 22 bearing cap bolts as shown. HINT: Each bolt length is indicated in the illustration. Bolt length: 25 mm (0.98 inch) for A 38 mm (1.50 inch) for B 52 mm (2.05 inch) for C 72 mm (2.83 inch) for D 94 mm (3.70 inch) for E 11. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Torque: Bolt A: 7.5 Nm (80 kgf-cm, 69 inch lbs.) Others: 16 Nm (160 kgf-cm, 12 ft. lbs.) 12. Boring the service bolt installed in the driven subgear upward by turning the hexagon wrench head portion of the camshaft with a wrench. 13. Remove the service bolt. Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle 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 operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 653 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Page 2316 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Page 4654 Engine Room R/B Details Page 4055 Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. Install shock absorber with coil spring. A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts. A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper, and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. Install new brake line. Using the SST, connect NEW brake line. SST P/N: 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. With ABS: Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: Install drive shaft lock nut. A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: Install grease cap. 31. Install front wheel. NOTE: Do NOT use an air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) Page 1718 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 4398 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front hub bearing play is within the specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the hub nuts and disc. Reinstall the disc 1/6 of a turnround from its original position on the hub. Install and torque the hub nuts. Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) (b) Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. (c) Repeat (a) and (b) until the disc has been installed on the 4 remaining hub positions. If the minimum runout recorded in (a) to (c) is less than the maximum disc runout, install the disc in that position. If the minimum runout recorded in (a) to (c) is greater than the maximum disc runout, replace the disc and repeat step 3. REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap tease glycol grease end disc brake grease to the parts indicated by the arrows. Page 3553 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 1875 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Page 6859 Fog/Driving Lamp Relay: Testing and Inspection INSPECT FOG LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 6271 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 6301 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 4176 32. Depress brake pedal several times. 33. Fill the brake reservoir with brake fluid and bleed brake system. 34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check). Repair Procedure No. 2 1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits. NOTE: It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. 2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on the rotor), replace the rotors using the service parts from the Parts Information table. 3. Check any new disc rotor for runout. 4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure. 5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts Information table. 6. Perform a road test. Page 3579 Transmission Mode Indicator - A/T: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1) Page 4830 Page 6882 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 5572 Glossary Of Terms And Symbols (Part 1) Page 4113 Required Tools & Material Page 1871 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Page 3027 Fuel Pressure: Testing and Inspection CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the front fuel pipe from the LH delivery pipe. d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and SST (adapter). SST 09268-45014 (09268-1190, 90405-06167) Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) e. Wipe off any splattered gasoline. f. Reconnect the negative (-) terminal cable to the battery. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a) to (e)) h. Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. i. Disconnect the TOYOTA hand-held tester from the DLC3. j. Start the engine. k. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) l. Stop the engine. m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45014 o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable to the battery. q. Check for fuel leaks. Page 5977 Page 1143 3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using Special Service Tool (SST), remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS speed sensor rotor (w/ABS)/spacer (w/o ABS). NOTICE: Take care not to scratch the serration of the speed sensor rotor. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY Page 2558 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 1994 CHART 23 Page 3462 Glossary Of Terms And Symbols (Part 2) Page 6839 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1921 CHART 14 Page 2317 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 3615 Valve Body: Service and Repair Lower Valve Body 1. COMPONENTS 2. SPRING, RETAINER AND CLIP Page 1144 1. INSTALL NEW BEARING a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a new snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat MP grease to the oil seal lip. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS) NOTICE: Do not scratch the serration of the speed sensor rotor. 5. 2WD: INSTALL NEW LOCK NUT a. Using SST install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) b. Using a chisel and hammer, stake the lock nut. Page 6533 Seat Belt Reminder Buzzer: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Page 1775 Engine Control Module: Locations Instrument Panel Page 4953 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Page 5283 1. Turn the temperature control knob to the full cold position. 2. Inspect the clearance between the water control valve lever and the lever stop. If the lever does not contact the lever stop, proceed to step 3. 3. If the lever does not contact the lever stop: A. Disengage the cable retaining clip. B. Pull up on the cable sheath until the water control valve lever contacts the lever stop. C. Re-fasten the cable retaining clip. Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation Page 3172 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. Page 2338 Glossary Of Terms And Symbols (Part 1) Page 4240 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 6557 Glossary Of Terms And Symbols (Part 2) Page 6326 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5769 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5805 Glossary Of Terms And Symbols (Part 1) Specifications Vacuum Brake Booster: Specifications Brake Booster Mounting Bolts 13 Nm Page 3382 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 5153 DISASSEMBLY 1. 2WD: REMOVE GREASE CAP a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 2. 4WD: REMOVE OIL SEAL (INSIDE) a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). Page 4084 Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). ^ 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Page 3190 Knock Sensor (Part 2) Page 6168 The spring properties of the rubber cushion of each of the body mounts have been optimized in order to improve the vehicle's riding comfort and to reduce noise and vibration. Page 3705 c. Suspend the front side of the propeller shaft. d. Place matchmarks on the transfer and propeller shaft flanges. e. Remove the 4 nuts and washers. f. Remove the propeller shaft from the transfer. 2. REMOVE REAR PROPELLER SHAFT a. Place matchmarks on the transfer and propeller shaft flanges. b. Remove the 4 nuts and washers, and disconnect the propeller shaft from the transfer. c. Suspend the front side of the propeller shaft. d. Remove the 2 mounting bolts and center support bearing. e. Place matchmarks on the differential and propeller shaft flanges. f. Remove the 4 bolts, washers and nuts. g. Remove the propeller shaft from the differential. DISASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. Rear propeller shaft: SEPARATE PROPELLER SHAFT AND INTERMEDIATE SHAFT a. Place the matchmarks on the flanges. b. Remove the 4 nuts, bolts and washers. 2. Rear propeller shaft: REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT a. Using a hammer and chisel, loosen the staked part of the nut. Testing and Inspection Volt Meter Gauge: Testing and Inspection INSPECT VOLT GAUGE SYSTEM Measure the resistance between terminals A and B. Resistance: Approx. 347 ohms If resistance value is not as specified, replace the gauge. Page 2567 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Brakes - Front Brakes Vibrate Upon Application Technical Service Bulletin # BR004R-02 Date: 050404 Brakes - Front Brakes Vibrate Upon Application BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '05 Tundra September 12, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The following sections have been updated, expanded, or added: Introduction, Warranty Information, Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB. ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque specification in step 24, was changed. ^ September 8, 2003: A torque specification in step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improvements have been made to various brake components to help improve this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown. Production Change Information Locations Fusible Link: Locations Driver Side J/B And Integration Relay Page 5789 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 6212 Cruise Control (Part 1) Page 1502 g. Reinstall the camshafts. h. Reinstall the timing belt. i. Recheck the valve clearance. 11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP COVER Page 5488 NOTE: Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure. NOTE: If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the seat belt after it is completely dried, to confirm proper operation. Page 6705 Brake Lamp: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2099 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Page 333 Wheel Speed Sensor: Diagrams Page 6412 Key Reminder Switch: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 6661 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 2278 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 6418 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 704 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Page 4356 32. Depress brake pedal several times. 33. Fill the brake reservoir with brake fluid and bleed brake system. 34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check). Repair Procedure No. 2 1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits. NOTE: It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. 2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on the rotor), replace the rotors using the service parts from the Parts Information table. 3. Check any new disc rotor for runout. 4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure. 5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts Information table. 6. Perform a road test. Page 1220 Piston Ring: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Testing and Inspection Power Seat Switch: Testing and Inspection Slide Switch Front Tilt Switch Rear Lifter Switch Reclining Switch INSPECT POWER SEAT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1370 Throttle Body (Part 1) Page 5399 a. Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700 1. Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. 2. Check functioning of the SST. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. 3. Disconnect the SST from the battery. b. Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. 1. While turning the steering wheel right / left, remove the 3 screws and column lower cover. 2. Disconnect the airbag connector of the spiral cable. Page 3237 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4395 3. REMOVE CALIPER Remove the 2 mounting bolts and caliper. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) 4. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 5. REMOVE 2 PADS AND 4 ANTI-SQUEAL SHIMS NOTICE: The anti-rattle spring and clip can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill brake reservoir with brake fluid and bleed brake system. - Check for leaks. Engine - Accessory Drive Belt Squealing Noise Drive Belt: All Technical Service Bulletins Engine - Accessory Drive Belt Squealing Noise ENGINE EG026-06 REVISED Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '06 Tundra April 21, 2006 TSB REVISION NOTICE: ^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered. Previous versions of this TSB should be discarded. Introduction Some customers may experience an abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor bracket, and revised installation procedure have been developed to address this condition. Applicable Vehicles ^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Parts Information Warranty Information Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 1592 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 88 kPa Page 1970 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Diagram Information and Instructions Horn: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Specifications Brake Pedal Assy: Specifications Brake Pedal Assembly Pedal Height 164-174 mm Reserve Pedal Height >95 mm Pedal Free Play (1) 1-3 mm Free play to the first point of resistance (between the clevis and the pin) Pedal Free Play (2) 1-6 mm Total pedal free play Stop Light Switch Clearence 0.5-2.4 mm Push Rod Lock Nut 25 Nm Page 5053 II. Identification of Affected Vehicles Testing and Inspection Daytime Running Lamp Resistor: Testing and Inspection INSPECT DAYTIME RESISTOR CONTINUITY If continuity is not as specified, replace the resistor. Page 4816 Driver Side J/B And Integration Relay Page 6534 Seat Belt Reminder Buzzer: Testing and Inspection KEY REMINDER AND SEAT BELT WARNING B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Replacement Requirements Clockspring Assembly / Spiral Cable: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. Page 1305 1. Remove the engine under cover. 2. Drain the engine coolant. 3. Remove the intake air connector assembly. 4. Remove the radiator fan shroud. 5. Remove the drive belt, fan, fluid coupling, and fan pulley. 6. Without disconnecting the power steering fluid lines, remove the power steering pump. HINT: Suspend the power steering pump securely. 7. Remove the drive belt idler pulley. 8. Remove the right hand (RH) No. 3 timing belt cover. 9. Remove the No.2 timing belt cover. 10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting bracket. HINT: Suspend the A/C compressor securely. 11. Disconnect the A/C compressor mounting bracket. Front Fluid - Differential: Service and Repair Front FILL DIFFERENTIAL WITH HYPOID GEAR OIL Page 5575 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Locations Instrument Panel Testing and Inspection Idle Up Control Valve: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start the engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rotations decrease when the vacuum hose of the air control valve is pinched. d. Check that the engine rotations increase when the hose is released. Page 5992 Roof Headlining Locations Page 2432 CHART 20 Page 942 1. Remove the engine under cover. 2. Drain the engine coolant. 3. Remove the intake air connector assembly. 4. Remove the radiator fan shroud. 5. Remove the drive belt, fan, fluid coupling, and fan pulley. 6. Without disconnecting the power steering fluid lines, remove the power steering pump. HINT: Suspend the power steering pump securely. 7. Remove the drive belt idler pulley. 8. Remove the right hand (RH) No. 3 timing belt cover. 9. Remove the No.2 timing belt cover. 10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting bracket. HINT: Suspend the A/C compressor securely. 11. Disconnect the A/C compressor mounting bracket. Page 2121 4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe. 5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. 6. Check if there is any fuel leakage. h. Observe these precautions when handling nylon tube. 1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by bending it. i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 2648 Engine Control Module: Service and Repair VEHICLE REPROGRAMMING Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM). Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign provides direction to do so. Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool - Vetronix Mastertech - J2534 Compatible Vehicle Interface (Toyota validated and approved) REPROGRAMMING WITH SCANTOOL Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool, or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the authentic Toyota factory scantool software which runs on either of the above mentioned scantools. Scantool software version requirements are specified in applicable Technical Service Bulletin (TSB)/Service Communication (SC) documents. The Toyota/Lexus factory scantool and/or authentic factory software program cards can be purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card - P/N 01002593-005 for the "stand alone" program card Program cards are provided with the latest production version software available at time of purchase. Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system - Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software - Toyota/Lexus factory scantool program card - PC Interface Cable (P/N 01001090) to transfer data from PC to scantool - Calibration CD (00456-REPRG-001) REPROGRAMMING WITH J2534 INTERFACE Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface - Toyota Calibration Update Wizard software (available on calibration CD) - Personal Computer running Microsoft Windows 2000/XP or later operating system - Calibration CD (00456-REPRG-001) Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on this list. Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that their hardware works safely and efficiently with their products. Every device listed on this page has been thoroughly tested and validated on Toyota, Scion and Lexus vehicles. It is important to understand that only the specific devices, firmware, DLLs and APIs listed here have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware, DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's control; in some cases, changes made to device hardware/software can negatively impact reprogramming performance. Toyota makes every effort to continue to work with J2534 interface manufacturers to ensure continued product compatibility as the respective products evolve. Requirement for device: Supplier Device Name Version (Firmware* / DLL* / API*) Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04) Actia PassThru+ XS (02.01 / 02.01 / 04.04) Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04) EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04) Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04) Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04) * Original validated firmware/DLL versions may be superceded by the device manufacturer. Contact the device manufacturer if you are unable to find the versions listed above. Support OS: OS Name and Version: Page 6431 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4527 Battery: Testing and Inspection ON-VEHICLE INSPECTION 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. 1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance-Free Battery: If under the lower level, replace the battery (or add distilled water if possible) and check the charging system. Except Maintenance-Free Battery: If under the lower level, add distilled water. 2. Except Maintenance-Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 - 1.29 at 20 °C (68 °F) If the specific gravity is less than specification, charge the battery. 3. Maintenance-Free Battery: CHECK BATTERY VOLTAGE a. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. b. Turn the ignition switch OFF and turn off the electrical systems. Page 4732 Fuse: Application and ID Engine Room R/B Fuse Applications (Part 1) Page 4172 A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. SST P/N: 09950-60020 (09951-00810) SST P/N: 09950-70010 (09951-07150) 16. Install new bearing. A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. SST P/N: 09527-17011 SST P/N: 09950-60020 (09951-00910) B. Using snap ring pliers, install a NEW snap ring. 17. Install new oil seal (outside). A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). SST P/N: 09223-15030 Page 410 Glossary Of Terms And Symbols (Part 2) Page 919 c. Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it. 17. TIGHTEN CRANKSHAFT PULLEY BOLT Using SST, install the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 245 Nm (2,500 kgf-cm, 181 ft. lbs.) 18. INSTALL FAN BRACKET Install the fan bracket with the 2 bolts and 2 nuts. Torque: 12 mm head 16 Nm (160 kgf-cm, 12 ft. lbs.) for (A) 14 mm head 32 Nm (330 kgf-cm, 24 ft. lbs.) for (B) HINT: Each bolt length is indicated in the illustration. Bolt Length: 106 mm (4.17 inch) for 12 mm head (A) 114 mm (4.49 inch) for 14 mm head (B) 19. w A/C: INSTALL A/C COMPRESSOR 20. INSTALL NO.2 TIMING BELT COVER Install the No.2 timing belt cover with the 2 bolts. Page 4069 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: Page 6990 - Let the primer coating dry for 3 minutes or more. - Do not keep any of the opened Primer G for later use. 9. APPLY ADHESIVE a. Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table. b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive as shown in the illustration. A: 12 mm (0.47 in.) B: 8 mm (0.31 in.) 10. INSTALL WINDSHIELD GLASS AND MOULDING a. Install the glass, aligning the reference marks using a suction rubber. HINT: Check that stoppers engage correctly viewing. b. Lightly press the glass front surface for close contact. Page 568 CHART 24 Page 214 Engine Control Module: Specifications Terminals Of ECU - Connector Pinouts (Part 2) Page 5579 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Brakes - Vibration From Front Brakes Technical Service Bulletin # BR004R-02 Date: 040924 Brakes - Vibration From Front Brakes BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra September 16, 2002 TSB REVISION NOTICE: ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque speification, step 24, was changed. ^ September 8, 2003: A torque specification, step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 2347 Engine Control Module: Connector Views Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Page 614 CHART 2 CHART 3 CHART 4 Page 4749 Glossary Of Terms And Symbols (Part 1) Page 523 A/F and 02 Sensor Identification Page 465 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Page 4803 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 3011 - Be careful not to drop the injectors when removing the delivery pipes. - Pay attention to put any hung load on the injector to and from the side direction. a. Remove the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. b. Remove the bolt, 2 union bolts, 4 gaskets and front fuel pipe. c. Disconnect the 8 injector connectors. d. Remove the 4 nuts holding the delivery pipes to the lower intake manifold. e. Remove the 2 delivery pipes, 8 injectors, 4 spacers and 8 insulators. f. Remove the O-ring and grommet from each injector. INSTALLATION 1. INSTALL INJECTORS AND DELIVERY PIPES NOTE: Be careful not to drop the injectors when installing the delivery pipes. - Pay attention to put any hung load on the injector to and from the side direction. a. Install a new grommet to each injector. b. Apply a light coat of gasoline to a new O-rings and install it to each injector. c. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 8 injectors. d. Position injector connector outward. e. Place the 4 spacers and 8 new insulators on the intake manifold. f. Place the 2 delivery pipes and injectors assemblies on the lower intake manifold. g. Temporarily install the 4 nuts. h. Install the front fuel pipe with the bolt, 4 new gaskets and 2 union bolts. Torque: Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 1453 Timing Belt Tensioner: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Timing Belt; Service and Repair. Page 2946 Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under these conditions: 1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor. Page 5056 Page 1510 Page 6987 c. Cut the adhesive by pulling the piano wire around it. d. Remove the glass. NOTE: Leave as much of the adhesive on the body as possible when cutting off the glass. INSTALLATION 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY a. Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. b. Clean the cutting surface of the adhesive with a shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. CLEAN REMOVED GLASS a. Remove the damaged stoppers and dam. b. Using a scraper, remove the adhesive sticking to the glass. c. Clean the glass with cleaner. NOTE: Do not touch the glass after cleaning it. Page 6592 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 4582 e. Install new terminal C kit parts. 1. Temporarily install a new terminal insulator (inside). 2. Temporarily install a new contact plate. 3. Temporarily install a new terminal bolt. 4. Temporarily install a new O-ring. 5. Temporarily install a new terminal insulator (outside). 6. Temporarily install a new wave washer. 7. Temporarily install a new terminal nut. NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction. f. Temporarily tighten the terminal nuts. g. Tighten terminal nuts. 1. Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 lbf) NOTE: Gauge Pressure - Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Page 5556 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 6473 Oil Pressure Sender: Testing and Inspection INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi). If operation is not as specified, replace the switch. 5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a. Disconnect the connector from the sender gauge. b. Check that no continuity exists between the terminal and ground with the engine stopped. c. Check that continuity exists between the terminal and ground with the engine running. HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi). If the continuity is not as specified, replace the sender gauge. Page 574 Page 887 d. Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. e. Adjust the spark plug electrode gap. Electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) g. Reinstall the ignition coils (with igniter). Page 3037 Fuel Pump Relay: Testing and Inspection Circuit Opening Relay CIRCUIT OPENING RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN) 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL RELAY BOX COVER Page 4777 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Ground Locations Trailer Connector: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 4551 a. Install the pulley to the rotor shaft by tightening the pulley nut by hand. b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) c. Check that SST (A) is secured to the pulley shaft. d. Mount SST (C) in a vise. e. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). f. To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf) g. Remove the generator from SST (C). h. Turn SST (B), and remove SST (A and B). 5. INSTALL RECTIFIER HOLDER Page 1430 Timing Belt: Service and Repair Page 2974 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Page 4309 Parts Information NOTE: Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly. Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Page 4919 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Diagram Information and Instructions Relay Box: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 1329 Oil Filter: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Oil; Service and Repair. Page 2100 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Page 5953 Page 5720 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 4061 Required Tools & Material Page 3231 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2011 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the oxygen sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2 c. Reconnect the oxygen sensor connector. 2. INSPECT OPERATION OF HEATED OXYGEN SENSORS Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not as specified, replace the main sender gauge. INSPECT FUEL LEVEL WARNING SWITCH a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and check that the bulb lights up. HINT: It will take a short time for bulb to light up. b. Submerge the switch in fuel, and check that the bulb goes out. If operation is not as specified, replace the sender gauge. Page 5533 The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender Worksheet shown. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place an order through Dealer Daily. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label on the part and review the "Owner Instruction Sheet" with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer's file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper fitting to individual customers. Page 41 INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 CONTINUITY If continuity is not as specified, replace the relay. Page 2722 Applicable Vehicles Page 6347 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 6679 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 3460 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3817 5. INSPECT ACTUATOR OPERATION a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD -> 4HI position. b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 2WD position. Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2330 Engine Control Module (ECM) Page 2301 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 1828 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Page 1977 CHART 1 Page 2635 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4817 Driver Side J/B And Integration Relay Inner Circuit Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection 5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire harness side connector. Front Diagrams Page 5110 Page 5028 2. DISCONNECT RH AND LH TIE ROD ENDS a. Remove the cotter pin and nut. b. Using SST, disconnect the tie rod end from the lower ball joint. SST 09610-20012 c. Employ the same manner described to the other side. 3. REMOVE POWER STEERING GEAR SET BOLTS AND NUTS 4. DISCONNECT STABILIZER BAR LINK FROM LOWER SUSPENSION ARM Remove the nut and disconnect the stabilizer bar link from the lower suspension arm. HINT: If the ball joint turns together with nut, use a hexagon (6 mm) wrench to hold the stud. 5. DISCONNECT SHOCK ABSORBER FROM LOWER SUSPENSION ARM a. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. b. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. c. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. Page 416 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4541 a. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. b. Reverse the polarity of the tester probes and repeat step (a). c. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 8. INSPECT NEGATIVE RECTIFIER a. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. b. Reverse the polarity of the tester probes and repeat step (a). c. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 9. INSPECT BEARING Check that the bearing is not rough or worn. If necessary, replace the bearing. Page 2569 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 5517 Seat Belt: Diagrams Seat Belt Page 2242 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Testing and Inspection Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Four Wheel Drive Selector Relay; Testing and Inspection; Procedures. Page 68 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 1969 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 4713 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 5768 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair ON-VEHICLE REPAIR 1. 5VZ-FE: DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission. 2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 4. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR NOTICE: Be careful not to twist the wire harness. 6. CONNECT OIL COOLER PIPE a. Install the elbow to the transmission. Page 2804 Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Gauge: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1998 Electrical Specifications Resistance Page 74 Lamp Control Module: Description and Operation LIGHT AUTO TURN OFF SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 9 of the integration relay through ECU IG fuse. Voltage is applied at all times to TERMINAL 6 of the integration relay through the TAIL fuse, and through the HEAD relay coil side [w/o daytime running light] or through the daytime running light relay (Main) [w/ daytime running light]. 1. NORMAL LIGHTING OPERATION With the light control SW turned to TAIL position, a signal is input into the integration relay. Due to this signal, the current flowing to TERMINAL 6 of the relay flows to TERMINAL 14 of the light control SW to TERMINAL 16 to GROUND, and taillights to turn on. With the light control SW turned to HEAD position, a signal is input into the integration relay. Due to this signal, the current flowing to the relay flows to TERMINAL 13 of the light control SW to TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the lights on. The taillight circuit is same as above. 2. LIGHT AUTO TURN OFF OPERATION With light on and ignition SW turned off (Input signal goes to TERMINAL 9 of the relay), when the driver's door is opened (Input signal goes to TERMINAL 14 of the relay), the relay operates and the current is cutoff which flows from TERMINAL 6 of the relay to taillight circuit and headlight circuit. As a result, all lights are turned off automatically. Page 5916 Page 2489 CHART 18 CHART 19 Locations Engine Room R/B Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill With Manual Transmission 10.6 qt (US) With Automatic Transmission 12.3 qt (US) Page 6252 Splice Location B11 Page 1894 Engine Bank Identification Page 4518 8. Select the appropriate model and press the NEXT soft key. 9. Select OEM battery type and press the NEXT soft key. 10. Choose the correct battery (model number and CCA) and press the NEXT soft key. 11. Aim the infrared (IR) temperature measurement sensor at the negative (-) battery post and press the NEXT soft key. Page 1947 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Page 4574 REMOVAL 1. REMOVE THROTTLE BODY COVER 2. DISCONNECT ACCELERATOR CABLE 3. REMOVE INTAKE AIR CONNECTOR Page 4440 4. REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) 5. REMOVE 2 PISTONS AND SPRINGS (a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. (b) Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle. NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged. - At the time of reassembly, be careful not to damage the rubber lips on the pistons. (c) Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until the No. 2 piston and spring drop out of the cylinder. HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 inch). INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING If necessary, clean or replace the cylinder. 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 2725 A/F and 02 Sensor Identification Page 4615 Fuse: Application and ID Engine Room R/B Fuse Applications (Part 1) Page 676 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3640 Fluid - Differential: Service and Repair Rear FILL DIFFERENTIAL WITH HYPOID GEAR OIL Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST w/ INTERMITTENT If continuity is not as specified, replace the switch. Page 3001 Fuel Injector: Locations Injector (Part 1) Page 2183 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Page 6588 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 4600 Glossary Of Terms And Symbols (Part 2) Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminals and the switch body with the switch ON (switch pin released: opened door). b. Check that no continuity exists between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. Page 1056 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Page 1318 Engine Oil: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection; Procedures. Page 29 Audible Warning Device Control Module: Testing and Inspection LIGHT AUTO TURN OFF HEAD RELAY 2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position. Closed with the engine running and the parking brake lever released (w/ daytime running light) C15 LIGHT CONTROL SW [COMB. SW] 13 - 16 : Closed with light control SW at HEAD position 14 - 16 : Closed with light control SW at TAIL or HEAD position D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Continuity with the front LH door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with the ignition SW at ON position 14 - GROUND : Continuity with the front LH door open 3, 6 - GROUND : Always approx. 12 volts 8 - GROUND : Always continuity POWER WINDOW D16, D17 DOOR COURTESY SW LH, RH 1 - GROUND : Continuity with door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with ignition SW at ON position 3 - GROUND : Always approx. 12 volts 14 - GROUND : Continuity with front LH door open (Standard cab) 14 - GROUND : Continuity with each LH door open (Access cab) 15 - GROUND : Continuity with front RH door open (Standard cab) 15 - GROUND : Continuity with each RH door open (Access cab) P9 POWER WINDOW CONTROL SW RH 4 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is turned off, but if a door is open in the 45 seconds period, voltage will drop to 0 volts P10 POWER WINDOW MASTER SW 1 - GROUND : Always continuity 9 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is turned off, but if a door is opened in this 41.5 - 44.5 seconds period, voltage will drop to 0 volts 3 - GROUND : Approx. 12 volts with ignition SW at ON position and master SW at UP position 4 GROUND : Approx. 12 volts with ignition SW at ON position and master SW at DOWN or AUTO DOWN position WINDOW LOCK SW Open with window lock SW at LOCK position DOOR LOCK CONTROL INTEGRATION RELAY 8 - GROUND : Always continuity 3 - GROUND : Always approx. 12 volts Page 798 Vehicle Speed Sensor NO.2 Page 5987 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTE: Page 3991 Anti-Lock Brake System Page 6883 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 6208 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2440 CHART 25 Page 5082 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6010 Page 6317 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 225 Glossary Of Terms And Symbols (Part 1) Page 5426 a. Install the front airbag sensors with the 4 bolts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) HINT: Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. NOTE: Connection of the connector is done after the sensor has been installed. - Make sure the sensor is installed with the specified torque. - If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with a new one. - The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. b. Connect the front airbag sensor connectors. c. Install the air cleaner assembly. d. 2UZ-FE engine: Install the battery tray, battery and battery carrier. Page 2419 O2S Application Table O2S Failure Threshold Charts Page 736 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Page 651 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 3829 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Grade ................................................................................................................................................... ............................................................ GL-4 or GL-5 Viscosity ........................................................... ................................................................................................................................................ SAE 75W-90 Page 5915 Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 813 c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 4LO position. d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO -> 4HI position. HINT: When inspecting the operation described, use a heater main relay. NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing. Page 4714 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 4690 Relay Box: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 1739 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 6415 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 6356 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5139 2. DISCONNECT SHOCK ABSORBER FROM LOWER SUSPENSION ARM a. Remove the shock absorber lower side set nut and washer. NOTICE: Do not remove the bolt. b. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. c. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. 3. REMOVE SHOCK ABSORBER WITH COIL SPRING Remove the 3 nuts and shock absorber with the coil spring. DISASSEMBLY REMOVE SUSPENSION SUPPORT AND COIL SPRING a. Using Special Service Tool (SST), compress the coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: ^ Make sure that the suspension support is free from the coil spring. ^ Do not compress the coil spring more than necessary. ^ Do not use an impact wrench. It will damage the SST. ^ Do not make your position at the top side of the shock absorber. b. Remove the suspension support center nut. c. Remove the 2 retainers, cushion, suspension support and coil spring. INSPECTION INSPECT SHOCK ABSORBER Page 2872 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1722 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 6833 Glossary Of Terms And Symbols (Part 1) Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY a. remove the reservoir tank cap and strainer. b. Disconnect the connector. c. Check that no continuity exists between the terminals with the switch OFF (float up). d. Use siphon, etc. to take fluid out of the reservoir tank. e. Check that continuity exists between the terminals with the switch ON (float down) f. Pour the fluid back in the reservoir tank. If operation is not as specified, replace switch. Page 3555 Transmission Mode Indicator - A/T: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 117 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Page 4419 DISASSEMBLY 1. DISCONNECT CONNECTOR (a) Remove the screw and clamp from the ABS actuator. Torque: 2.9 Nm (30 kgf-cm, 26 inch lbs.) (b) Disconnect the connector. 2. REMOVE ABS ECU Using a hexagon wrench (4 mm), remove the 4 bolts and ABS ECU. Torque: 4.4 Nm (45 kgf-cm, 39 inch lbs.) NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing damage on the valve body. If the dirt and the like is stuck to the sealing surface, use plastic tools or soft objects to remove the dirt. Do not use chemical solvents. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 5534 This bulletin contains the following information: Procedure and Sample Label Application Charts Pages Part Number Information Owner Instructions Seat Belt Extender Worksheet Applicable Vehicles ^ 2001 through 2003 model year Toyota vehicles. Warranty Information Procedure 1. Customer requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet. 3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places an order for the part through Dealer Daily. 4. Dealer receives Seat Belt Extender and calls the customer to check the fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet. 6. Dealer places copy of the completed Worksheet in the customer's records. Page 2329 Engine Control Module: Locations Instrument Panel ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 5648 Air Bag Deactivation Switch: Testing and Inspection PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off switch connector on the airbag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 492 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Page 899 g. Reinstall the camshafts. h. Reinstall the timing belt. i. Recheck the valve clearance. 11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP COVER Electrical Specifications Resistance Page 4930 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4523 The charger starts charging upon completion of testing. The screen displays the status of charge. 13. Read or print the battery test results. P 1/4: BATTERY RESULTS P 2/4: STATE OF CHARGE (SOC) P 3/4: STATE OF HEALTH (SOH) P 4/4: WARRANTY CODE To print: Align the Midtronics IR Printer (P/N 00002-A0870, component of P/N 00002-V8150-KIT) in front of the IR port on the charger and select the PRINT soft key. Battery Charging Results Once the test completes, proceed with 1 of the 3 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: "GOOD BATTERY" Return the battery to service. 2. Battery Condition: "REPLACE BATTERY" Replace the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out-of-vehicle test before replacing it. 3. Battery Condition: "BAD CELL-REPLACE" Replace the battery. The decision indicates a bad cell within the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. Page 4122 INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. 09023-00100 Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 3105 1. Insert the wave washer into the throttle control motor cover. 2. Align the pin holes of the throttle control motor with the positioning pins of the throttle control motor cover. 3. Attach the grommet to the throttle control motor cover. 4. Install the throttle control motor with the 3 screws. Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf) 5. Apply the grease thinly on the whole surface of the gear teeth. NOTE: Do not apply the grease other than specified because grease has been already applied to the component to be replaced. 6. Install the washer as shown in the illustration. 7. Align the pin hole of the throttle control motor cover with the positioning pin of the throttle body. 8. Install the throttle control motor cover and motor assembly with the 6 screws. Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf) 9. Connect the throttle control motor connector to the connector bracket. d. Reinstall and adjust the throttle position sensor. (See step 1) 3. REPLACE ACCELERATOR PEDAL POSITION SENSOR a. Remove the 3 set screws and accelerator pedal position sensor. Page 3094 Throttle Body (Part 2) Page 5008 A. Move the hub up and down by hand (most models with wishbone suspension): a. Remove the tire. b. Install the 2 lug nuts. c. Inspect the free play while moving the lug nuts up and down at a force of 67 lbf (294 N, 30 kgf). B. Move the lower arm using a lever (some models with double wishbone type suspension): a. Lift up the vehicle. b. Place the tip of the lever to the wheel and inspect the free play while moving the lower arm up and down. C. Move the lower arm by hand (all models with strut type suspension and some models with wishbone type suspension): a Lift up the vehicle. b. Inspect the free play while moving the lower arm up and down at a force of 67 lbf (294 N, 30 kgf). 2. Inspect Upper Ball Joint Free Play A. Move the upper arm by hand (models with the LOWER control arm linked by a torsion bar, and all models using a coil spring). a. Remove the front tire. b. Inspect the free play while moving the upper arm up and down at a force of 67 lbf (294 N, 30 kgf). B. Move the tire with a lever (models with the UPPER control arm linked by a torsion bar). Page 680 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 6686 Electronically Controlled Transmission And A/T Indicator (Part 3) Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 647 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the oxygen sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2 c. Reconnect the oxygen sensor connector. 2. INSPECT OPERATION OF HEATED OXYGEN SENSORS Page 943 12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding the bracket forward (refer to illustration). 13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following sequence: bolt 2, bolt 1, bolt 3. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) 14. Remove the accessory drive belt tensioner. 15. Install the NEW accessory drive belt tensioner. 16. Reassemble in the reverse order of disassembly. 17. Refill cooling system. Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Page 1763 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 2385 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST w/ INTERMITTENT If continuity is not as specified, replace the switch. Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle 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 operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 2042 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3241 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Component Tests and General Diagnostics Brake Light Switch: Component Tests and General Diagnostics w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. w/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1744 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 4133 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. ^ 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. ^ 09710-28012-01 (09710-07031) ^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 4023 3. BLEED BRAKE LINE (a) Connect the vinyl tube to the caliper. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. SST 09751-36011 (c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (d) Repeat (b) and (c) until all the air in the fluid has been bled out. Torque: (Bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.) (e) Repeat the procedure on the previous page to bleed the air out of brake line for each wheel. 4. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 LOAD SENSING PROPORTIONING AND BY-PASS VALVE ON-VEHICLE INSPECTION 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab: 5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.) 2. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi) Component Locations Ignition Switch And Key Unlock Warning Switch Page 2321 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 1787 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 6530 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3305 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2796 A/F and 02 Sensor Identification Page 181 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 4879 a. Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight. b. Check the flow control valve for leakage. Close one of the holes and apply compressed air - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi) into the opposite side, and confirm that air does not come out from the end holes. If necessary, replace the valve with one having the same letter as inscribed on the front housing. Inscribed mark: A, B, C, D, E or F 4. INSPECT SPRING Using vernier calipers, measure the free length of the spring. Minimum free length: 33.2 mm (1.307 inch) If it is not within the specification, replace the spring. REPLACEMENT NOTICE: When using a vise, do not overtighten it. IF NECESSARY, REPLACE OIL SEAL Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 5757 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 5559 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 2498 CHART 25 Testing and Inspection Seat Belt Buckle Switch: Testing and Inspection Bench Type and Passenger Side: INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. (w/o Bench Type (Driver Side): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 3 and 4 on the switch side connector with the switch ON (elt fastened). b. Check that no continuity exists between terminal 3 an 4 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. Separate Type (w/ Power Seat): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. Page 1521 Coolant: Testing and Inspection INSPECTION HINT: Check the coolant level when the engine is cold. 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the "LOW" and "FULL" lines at normal temperature (20°C (68°F)). If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the "FULL" line. 2. CHECK ENGINE COOLANT QUALITY a. Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. There should not be any excessive deposits of rust or scale around the radiator cap or radiator hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. c. Reinstall the radiator cap. Page 3292 5. INSPECT ACTUATOR OPERATION a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD -> 4HI position. b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 2WD position. Page 626 Page 4168 4. With ABS: Disconnect ABS speed sensor and wire harness clamp from steering knuckle. Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. Disconnect brake line. Using the following SST, disconnect the brake line. Use a container to catch the brake fluid. SST P/N: 09023-00100 6. Remove brake caliper and disc. A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper, and disc. 7. Remove shock absorber. Page 2755 CHART 8 CHART 9 Page 4568 17. DO HOLD-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. TEST NOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. 1. DO PULL-IN TEST a. Disconnect the field coil lead wire from terminal C. b. Connect the battery to the magnetic switch as shown. Check that the pinion gear moves outward. 2. DO HOLD-IN TEST While connected as above with the pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out. 3. INSPECT CLUTCH PINION GEAR RETURN Page 6812 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5966 Page 65 Lamp Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminals and the switch body with the switch ON (switch pin released: opened door). b. Check that no continuity exists between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. Page 561 CHART 20 Page 621 CHART 14 Page 3593 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 6836 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3103 Throttle Body: Service and Repair Replacement REPLACEMENT NOTE: - To prevent deterioration, do not shock the throttle position sensor and accelerator pedal position sensor. - Mixing of the foreign objects may cause the gear locking, so thoroughly check that there is no stuck of any foreign objects and clean up if any. 1. REPLACE THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector on the lead wire. b. Remove the 2 set screws and throttle position sensor. c. Reinstall a new throttle position sensor. 1. Check that the throttle valve is under the condition of the opener opening angle (about 5.5 °). 2. Install the sensor to the place where is at 15 ° rotated to the right from the specified installation position. 3. Gradually turn sensor counterclockwise until it touches the throttle valve shaft, and temporarily tighten the 2 set screws. d. Connect the throttle position sensor connector on the lead wire. e. Adjust the throttle position sensor. 1. Connect the throttle position sensor connector. NOTE: Do not connect the accelerator pedal position sensor connector. 2. Connect the TOYOTA hand-held tester or OBD II scan tool to the DLC3. 3. Turn the ignition switch ON. Page 2610 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 5249 8. INSTALL CENTER CLUSTER INTEGRATION PANEL a. When replacing the heater control assembly: Pull off the cover. b. Install the center cluster integration panel, then connect the 2 connectors. c. Install the 5 screws. d. Install the 3 heater control knobs. Disassembly and Reassembly HEATER CONTROL ASSEMBLY DISASSEMBLY 1. REMOVE HEATER CONTROL CABLES a. Using a screwdriver, spread the claw of the cable clamp and disconnect the outer cable. HINT: Tape the screwdriver tip before use. b. Remove the inner cable from the heater control assembly. 2. REMOVE BLOWER SPEED CONTROL SWITCH a. Disconnect the connector. b. Remove the 2 screws. c. Remove the switch. Page 2746 Page 2912 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2623 Terminals Of ECU - Connector Pinouts (Part 1) Page 5386 Air Bag Deactivation Switch: Testing and Inspection PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off switch connector on the airbag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 4216 A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. 8. DISCONNECT LOWER BALL JOINT Page 3192 Step 1 Page 2476 Page 5942 Page 1114 Relay Box: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4673 Driver Side J/B And Integration Relay Page 1816 Page 2524 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 3916 Electronically Controlled Transmission And A/T Indicator (Part 2) Page 5573 Glossary Of Terms And Symbols (Part 2) Page 2633 Glossary Of Terms And Symbols (Part 1) Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... .......................................................... 0.15 - 0.25 mm Exhaust ........................................................... ............................................................................................................................................... 0.25 0.35 mm Page 1836 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Testing and Inspection Four Wheel Drive Selector Switch: Testing and Inspection INSPECTION 1. INSPECT 2WD -> 4HI SHIFT a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4 switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4 switch is in OFF position. HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be moved back and forth. - If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash. 2. INSPECT 4HI -> 4LO SHIFT Page 2660 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Page 1934 Page 6328 Cigarette Lighter: Testing and Inspection CIGARETTE LIGHTER AND POWER OUTLET C7 CIGARETTE LIGHTER 2 - GROUND : Approx. 12 volts with ignition SW at ON or ACC position 1 - GROUND : Always continuity P6, P7 POWER OUTLET 2 - GROUND : Approx. 12 volts with the ignition SW at ON or ACC position 1 - GROUND : Always continuity Page 4184 A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. 8. DISCONNECT LOWER BALL JOINT Page 6988 3. INSTALL NEW STOPPERS Attach new stoppers to the glass with the ceramic notches on the glass aligned with the stoppers as shown in the illustration. 4. INSTALL NEW DAM Install a new dam with double-stick tape as shown in the illustration. A: 7.0 mm (0.276 in.) NOTE: Do not touch the glass surface after cleaning it. 5. POSITION GLASS a. Place the glass in the correct position. b. Check that all contacting parts of the glass rim are perfectly even. c. Place reference marks between the glass and body. d. Remove the glass. Specifications Throttle Body (Part 1) Page 6084 Above are items that should be checked periodically and their frequency. Summary Chart for Long-Term Storage A combination of proper Vehicle Receipt, Pre-Delivery Service and Vehicle Storage is the only way to maintain factory fresh vehicles. Toyota's goal is to deliver 100% problem-free cars and trucks. With your commitment to quality and customer satisfaction, we can reach that goal. Review this TSB often and be sure new employees are aware of the policies and procedures out-lined herein, as individual training in proper inspection, pre-delivery service, and storage and handling techniques are essential to ensure high delivery quality. Here is a list of additional resources, which will help you with vehicle receipt, inspection and storage procedures. Reference and Training Materials ^ CRIB # 165, Acid Rain Paint Finish Damage - Prevention and Repair ^ UoT e-Learning Course E257 Vehicle Delivery Quality - Paint Finish Repair ^ Dealer Delivery Quality Operations Guide, P/N 00116-DDQ0G-98 ^ BO020-91, Prevention and Repair of Acid Rain Damage ^ BO05-04, New Vehicle Washing Schedule for Paint Protection ^ PG001-06, Battery Maintenance for In Stock Vehicle and Pre-Delivery ^ PA005-04, Iron Particle Rust Contamination Repair ^ PG005-94, Rapgard(TM) Removal Procedures ^ PG007-02, Wheel Film for Brake Rotor Rust Prevention ^ Maintenance for HV & Auxiliary Batteries, Refer to applicable HV models. Page 5583 Seat Belt Reminder Buzzer: Testing and Inspection KEY REMINDER AND SEAT BELT WARNING B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1840 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Page 2175 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Specifications Page 800 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ...................................................... 1,324 kPa or More Minimum Pressure ......................................... ........................................................................................................................................................... 981 kPa Difference Between Each Cylinder ........................................................................................ ......................................................................... 98 kPa or Less Brakes - Rear Brakes Vibrate Upon Application Brake Drum: All Technical Service Bulletins Brakes - Rear Brakes Vibrate Upon Application BRAKES BR003-02 REVISED Title: REAR BRAKE VIBRATION Models" '00 - '05 Tundra September 16, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. Parts Informations table has been updated. Required SSTs table has been added. The Warranty Information has been updated. The Diagnosis Procedure and Repair Procedure have been combined into one Repair Procedure section. The Repair Procedure section has been updated. PLEASE READ ENTIRE TSB. The previous TSB should be discarded. Introduction New brake drums have been introduced for use as service parts on 2000 - 2005 model year Tundra trucks to reduce rear brake vibration. The new drum has increased mass and rigidity. Applicable Vehicles 2000 - 2005 model year Tundra vehicles. Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Applicable Warranty*: The replacement of the Rear Axle Shaft is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * 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 systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Air Bag Systems/Testing and Inspection Page 5772 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Specifications Piston: Specifications Piston Diameter (STD) Mark 1 ............................................................................................................ ........................................................................................ 93.902 - 93.912 mm Mark 2 ....................... .............................................................................................................................................................. .............. 93.912 - 93.920 mm Mark 3 ................................................................................................. ................................................................................................... 93.920 - 93.930 mm O/S 0.50 ......... .............................................................................................................................................................. .......................... 94.402 - 94.430 mm Standard Oil Clearance ....................................................................................................................... ....................................................... 0.090 - 0.111 mm Maximum Oil Clearance ................................. ......................................................................................................................................................... 0.13 mm Page 3717 b. Check the spider bearing axial play. Maximum bearing axial play: 4WD rear propeller shaft: 0 mm (0 inch) 2WD and 4WD front propeller shaft: 0.05 mm (0.0020 inch) HINT: Install new spider bearings on the flange side in the procedure described. - When replacing the rear propeller shaft spider on 4WD vehicle, be sure that the grease fitting assembly hole is facing in the direction shown. Page 5610 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3464 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 5695 Page 5545 Warranty Information Procedure and Sample Label 1. Owner requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet. 3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places a Critical Order for the part through the IDN Parts Network. 4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet. 6. Dealer places copy of the completed Worksheet in the customer's records. Application Charts Sample Seat Belt Extender Customer Information Label Page 2915 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Page 4321 B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 5588 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 4424 Adjustment range: 112 - 128 mm (4.41 - 5.04 inch) HINT: One turn of the nut changes the fluid pressure as shown in the following specification. 7.4 kPa (0.76 kgf/cm, 11 psi) (c) Torque the lock nut. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body. Low pressure-Lower body High pressure-Raise body (e) Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be adjusted, inspect the valve body. 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with the load sensing spring or move it. (b) In this position. check the rear brake pressure If the measured value is not within the standard, replace the valve body. Page 6660 Transmission Mode Indicator - A/T: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 2786 Page 231 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 916 3. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. a. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler pulley and No.2 idler pulley, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. c. Install the timing belt on the crankshaft timing pulley, No.1 idler pulley and No.2 idler pulley. 4. INSTALL TIMING BELT COVER SPACER a. Install the gasket to the cover spacer. b. Install the cover spacer. 5. INSTALL TIMING BELT GUIDE Install the belt guide, facing the cup side outward. 6. INSTALL NO.1TIMING BELT COVER Install the timing belt cover with the 4 bolts. 7. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the crankshaft pulley. b. Using SST and a hammer, tap in the crankshaft pulley. SST 09223-46011 8. INSTALL DRIVE BELT TENSIONER Install the belt tensioner with the bolt and 2 nuts. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) HINT: Use a bolt 106 mm (4.18 inch) in length. 9. INSTALL GENERATOR Page 6821 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Specifications Axle Nut: Specifications Front Drive Shaft Lock Nut 235 Nm (173 ft.lb) Page 4081 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. ^ 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. ^ 09710-28012-01 (09710-07031) ^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 4048 4. With ABS: Disconnect ABS speed sensor and wire harness clamp from steering knuckle. Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. Disconnect brake line. Using the following SST, disconnect the brake line. Use a container to catch the brake fluid. SST P/N: 09023-00100 6. Remove brake caliper and disc. A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper, and disc. 7. Remove shock absorber. Page 3701 Drive/Propeller Shaft: Specifications PROPELLER SHAFT ASSEMBLY Specifications Camshaft Gear/Sprocket: Specifications Tightening Torque Crankshaft Pulley ................................................................................................................................ ...................................................................... 245 Nm LH, RH Camshaft Timing Pulleys ................... .......................................................................................................................................................... 108 Nm Page 5824 Front Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Page 6421 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 4423 Load Compensator: Testing and Inspection ON-VEHICLE INSPECTION 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab: 5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.) 2. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi) HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2 seconds. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Loosen the lock nut. (b) Adjust the length of the shackle No. 2. Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch) Diagrams Power Steering Pump: Diagrams POWER STEERING VANE PUMP REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Part 1 of 2 Page 1913 CHART 1 Page 4164 Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 2551 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 5103 II. Identification of Affected Vehicles Page 6684 Transmission Mode Indicator - A/T: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1) Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 89 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1915 CHART 5 CHART 6 Page 23 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 5015 Ball Joint: Testing and Inspection ON-VEHICLE INSPECTION INSPECT LOWER BALL JOINT EXCESSIVE PLAY ON-VEHICLE a. Remove the front wheel and install the hub nuts to the disc. b. Using a dial indicator, check the lower ball joint for excessive play when you push the hub nuts up and down with a force of 294 N (30 kgf, 66 ft. lbs.). Maximum: 0.5 mm (0.020 inch) Page 552 CHART 7 Page 6519 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5874 Wheel Arch Moulding Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3385 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Testing and Inspection Cargo Lamp Switch: Testing and Inspection INSPECT CARGO LIGHT SWITCH CONTINUITY a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster integration. c. Check the continuity exists between terminal 12 and terminal 1, with the switch ON. d. Check that no continuity exists between terminal 12 and terminal 1, with the switch OFF. If continuity is not as specified, replace the switch. Page 4629 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2239 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Page 2884 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 2795 Engine Bank Identification Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * 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 systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Locations Fusible Link: Locations Driver Side J/B And Integration Relay Page 3381 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Testing and Inspection Door/Trunk Ajar Indicator/Lamp: Testing and Inspection INSPECT OPEN DOOR WARNING LIGHT a. Disconnect the connector from the door courtesy switch and ground terminal on the wire harness side connector. b. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb. Page 3776 ^ If there are 2 alignment pins present the transmissionltransaxle assembly may be installed following the applicable Repair Manual procedure. NOTE: A missing alignment pin may result in failure of the transmissionltransaxle assembly. 2. Install the missing alignment pin(s). ^ Refer to the applicable Repair Manual procedure for location of the cylinder block rear side alignment pins. NOTE In the Repair Manual, the alignment pin is referred to as a "straight pin." Front Wheel Fastener: Service and Repair Front REPLACEMENT 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake caliper and disc. c. Support the brake caliper securely. 3. REMOVE HUB BOLT Using Special Service Tool (SST) and a screwdriver or an equivalent, remove the hub bolt. SST 09650-17011 4. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a screwdriver or an equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer. 5. INSTALL BRAKE DISC AND CALIPER a. Install the brake disc, caliper and 2 bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) b. Install the brake line clamp to the steering knuckle with bolt. Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.) 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 7. DEPRESS BRAKE PEDAL SEVERAL TIMES Page 2431 CHART 18 CHART 19 Page 569 CHART 25 Page 4304 32. Depress brake pedal several times. 33. Fill the brake reservoir with brake fluid and bleed brake system. 34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check). Repair Procedure No. 2 1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits. NOTE: It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. 2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on the rotor), replace the rotors using the service parts from the Parts Information table. 3. Check any new disc rotor for runout. 4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure. 5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts Information table. 6. Perform a road test. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair ON-VEHICLE REPAIR 1. 5VZ-FE: DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission. 2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 4. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR NOTICE: Be careful not to twist the wire harness. 6. CONNECT OIL COOLER PIPE a. Install the elbow to the transmission. Page 4694 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1771 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Page 1640 Water Pump: Service and Repair Page 2583 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 2668 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 3723 Flex Plate: Specifications Drive Plate Runout Maximum Runout 0.20 mm New Drive Plate Bolts Torque 83 Nm Page 6805 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Locations Supplemental Restraint System Page 463 Mass Air Flow (MAF) Meter Page 627 CHART 21 Service and Repair Planetary Gears: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair. Page 2059 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt Torque ............................................................................................................. .................................................... 245 Nm (181 ft.lb) Page 35 Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 609 Locations Hose/Line HVAC: Locations Refrigerant Line (Part 1) Page 3017 Fuel Pressure Regulator Page 3766 Transmission Mode Indicator - A/T: Description and Operation ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR SYSTEM OUTLINE The electronically controlled transmission electrically controls the, throttle pressure, lock-up pressure, and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls the gear shift timing and lock-up timing in response to the vehicle's driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection of the gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. GEAR SHIFT OPERATION When driving, the engine warm up condition is input as a control signal from the engine coolant temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA, VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. LOCK-UP OPERATION When the engine control module decides based on each signal that the lock-up condition has been met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the electronically controlled transmission solenoid to GROUND. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input to TERMINAL STP of the engine control module. As a result, the engine control module cuts the current to the solenoid to release the lock-up. 4. OVERDRIVE CIRCUIT - O/D main SW on When the O/D main SW is switched to ON position, a signal is input to TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range, through the control of the engine control module. - O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range through the control of the engine control module. When in the overdrive range already, shift down is made. Page 64 Glossary Of Terms And Symbols (Part 2) Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 629 Page 4766 Engine Compartment Instrument Panel Locations Page 4686 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1121 Relay Box: Connector Views Engine Room R/B Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 2. BLEED MASTER CYLINDER HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. SST 09023-00100 (b) Slowly depress the brake pedal and hold it. (c) Block off the outlet plug with your finger, and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. Diagrams Shifter A/T: Diagrams COLUMN SHIFT ASSEMBLY OVERHAUL W/ RELATED COMPONENTS Part 1 of 2 Page 2008 Oxygen Sensor: Mechanical Specifications Torque: Sensor 1 ................................................................................................................................. ............................................... 44 N.m (450 kgf.cm, 32 ft.lbf) Sensor 2 .............................................................................................................................................. .................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Page 1113 Glossary Of Terms And Symbols (Part 2) Brakes - Vibration From Rear Brake Drum: All Technical Service Bulletins Brakes - Vibration From Rear BRAKES BR001-01 January 12, 2001 Title: REAR BRAKE VIBRATION Models: '00 - '01 Tundra TSB Update Notice: The information contained in this TSB updates BR006-00, dated November 17, 2000. Revised text is underlined. New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the star wheel adjuster has been reduced from 30 to 26 teeth. Applicable Vehicles ^ 2000 - 2001 model year Tundra vehicles. Production Change Information Parts Information Repair Procedure 1. Grind rear brake drums with brake lathe to within serviceable limits. 2. If the drums are unserviceable or above maximum inside diameter, replace the drums. 3. If there is uneven wear on the lining, replace the left and right brake shoes. 4. Replace the parking brake shoe strut sets. 5. Adjust the parking brake to specifications. 6. Reinstall the rear wheels, and torque wheel nuts to: Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf) 7. Road test. Warranty Information Page 5928 Page 5781 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3871 a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4 switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and the 4HI indicator lights come on when the touch select high-low switch is in OFF position. HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position. - If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash. 3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals. Touch select 2-4 switch Touch select high-low switch: If continuity is not as specified, replace the center integration panel assembly. 4. INSPECT ACTUATOR RESISTANCE a. Using an ohmmeter, measure the resistance between terminals 1 and 2. Standard resistance: 0.3 - 100 Ohms b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground. Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the actuator assembly. Page 4000 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly Page 3446 Transmission Mode Indicator - A/T: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 5524 D. Check to be sure that the male pin of the tongue plate stopper has become deformed evenly in the hole of the female part and is firmly held to the belt webbing. Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SRS AIRBAG PRECAUTION CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front passenger airbag and failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a 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 described. 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. 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.) Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one. Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the SRS is completed, check the SRS warning light check. 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 systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. If the vehicle is equipped with a mobile communication system, refer to the precaution. Page 73 Light Auto Turn Off Page 2136 Spark Plug: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT SPARK PLUGS a. Remove the ignition coils (with igniter). b. Using a 16 mm plug wrench, remove the spark plugs. c. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. Recommended Spark Plug Page 4717 Glossary Of Terms And Symbols (Part 2) Paint - Paint Codes - All Paint: Technical Service Bulletins Paint - Paint Codes - All COLLISION REPAIR INFORMATION CRIB107 TITLE: 2001 PAINT AND REFINISH FORMULAS CODES SECTION: REFINISH BULLETIN #107 MODELS: ALL DATE: OCTOBER 2000 Attached for your reference is a list of all 2001 Toyota paint codes and the refinish formula codes for the following paint manufacturers: BASF, DuPont, PPG, Sherwin-Williams, Akzo Nobel, Spies-Hecker, ICI Autocolor and Standox. NOTE: The vehicle paint code is on the certification label which can be located on the driver side door jamb or the lower section of the "B" pillar. Please contact your local paint representative for the actual paint mixing formulas or if you need help in color matching. 2001 TOYOTA PAINT CODES AND COLOR NAMES Page 6093 Page 4683 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4215 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. ^ 09023-00100 6. REMOVE BRAKE,CALIPER AND DISC Testing and Inspection Four Wheel Drive Selector Switch: Testing and Inspection INSPECTION 1. INSPECT 2WD -> 4HI SHIFT a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4 switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4 switch is in OFF position. HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be moved back and forth. - If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash. 2. INSPECT 4HI -> 4LO SHIFT Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the slide rheostat, then read the rheostat indication. If resistance value is not as specified, replace the engine coolant sender gauge. Page 6527 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2861 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Engine Controls - Techstream(R) ECU Re-Flash Procedure PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 5998 Insert a screwdriver between the back panel upper garnish and body panel to remove the back panel upper garnish. 15. REMOVE QUARTER TRIM a. Standard cab: Remove the bolt and front seat outer belt floor anchor. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) b. Access cab: Remove the bolt and rear seat outer belt floor anchor. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) c. Using a screwdriver, remove the quarter trim belt hole cover. d. Standard cab: Using a screwdriver, remove the cap. e. Standard cab: Unfasten the bolt and remove front seat outer belt shoulder anchor. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) Page 3819 6. INSPECT LIMIT SWITCH CONTINUITY a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the transfer shift lever and after checking the operating sound, disconnect the connector and inspect the continuity between each terminal. HINT: When shifting the actuator fork shaft, connect the connectors. 7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check the combination meter. 9. INSPECT 4WD CONTROL ECU Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side connector from the back side. Page 2909 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3609 1. POSITION NEW NO. 1 GASKET ON UPPER VALVE BODY Align a new No. 1 gasket with each bolt hole. 2. POSITION VALVE BODY PLATE ON NO. 1 GASKET Align the plate with each bolt hole. 3. POSITION NEW NO. 2 GASKET ON PLATE Align a new No. 2 gasket with each bolt hole. 4. INSTALL 10 CHECK BALLS 5. INSTALL SPRING AND CHECK VALVE 6. INSTALL OIL STRAINER Install the 3 oil strainers to the plate. 7. PLACE UPPER VALVE BODY WITH PLATE AND GASKETS ON TOP OF LOWER VALVE BODY Align each bolt hole with the gasket in the valve body. NOTICE: Be careful that the check ball and strainer do not fall out. Page 1084 Fuse Block: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3380 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 871 4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe. 5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. 6. Check if there is any fuel leakage. h. Observe these precautions when handling nylon tube. 1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by bending it. i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 122 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Page 5151 3. 4WD: DISCONNECT DRIVE SHAFT a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut. 4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. REMOVE BRAKE CALIPER AND DISC a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake caliper and disc. NOTICE: Do not damage the brake tube. c. Support the brake caliper securely. 6. REMOVE SHOCK ABSORBER 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Page 4320 ^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) Page 4587 Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY Remove the relay box cover and starter relay. 2. INSPECT STARTER RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 3. INSPECT STARTER RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL STARTER RELAY Page 3743 Transmission Mode Indicator - A/T: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2573 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 3909 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 522 Engine Bank Identification Page 961 4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe. 5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. 6. Check if there is any fuel leakage. h. Observe these precautions when handling nylon tube. 1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by bending it. i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 5632 e. Dispose of front seat outer belt (with seat belt pretensioner). CAUTION: The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. - Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner. 1. Remove the disc wheel and SST. 2. Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts. Page 1686 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 909 6. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY a. Loosen the 4 nuts holding the fluid coupling to the fan bracket. b. Remove the drive belt. c. Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley. 7. DISCONNECT PS PUMP Remove the 3 bolts, and disconnect the PS pump from the engine. HINT: Suspend the PS pump securely. 8. REMOVE DRIVE BELT IDLER PULLEY Remove the pulley bolt, cover plate and idler pulley. 9. REMOVE RH NO.3 TIMING BELT COVER Remove the 3 bolts, nut and RH No.3 timing belt cover. 10. REMOVE LH NO.3 TIMING BELT COVER a. Disconnect the engine wire from the 2 wire clamps. b. Remove the 4 bolts and nut. c. Disconnect the camshaft position sensor wire from the wire clamp on the LH No.3 timing belt cover. d. Disconnect the camshaft position sensor connector from the connector bracket. e. Disconnect the camshaft position sensor connector. f. Remove the wire grommet from the LH No.3 timing belt cover. g. Remove the LH No.3 timing belt cover. h. Remove the bolt, nut and oil cooler pipe Page 982 Brake Fluid: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. Page 2339 Glossary Of Terms And Symbols (Part 2) Service and Repair Planetary Gears: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transfer Case; Service and Repair. Audio System - CD Player Skip Verification CD Changer: Technical Service Bulletins Audio System - CD Player Skip Verification SPECIAL SERVICE TOOLS SS003-05 Title: CD SKIP VERIFICATION USING TOYOTA MASTER CD Models: '01 - '06 All Toyota & '04 - '06 All Scion November 28, 2005 Introduction Toyota has developed a master CD to be used for customer complaints of the CD player skipping or CD player cannot read disc. This disc has been specially manufactured to test the performance of the Toyota CD players. Using this master CD will confirm that the radio exceeds Toyota's specification for CD player performance. Applicable Vehicles ^ 2001 - 2006 model year Toyota vehicles. ^ 2004 - 2006 model year Scion vehicles. Test Disc Specifications Warranty Information Page 5405 e. Install the SST. CAUTION: Place the disc wheel on the level ground. 1. Connect the connectors of SST to the steering wheel pad connector. SST 09082-00700, 09082-00760 NOTE: 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. 2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. f. Cover the steering wheel pad with a cardboard box or tires. - Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire - If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. - Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size : Must exceed the following dimensions- Width : 185 mm (7.87 in.) Inner diameter : 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTE: The tires may be marked by the airbag deployment, so use the redundant tires. Page 2809 CHART 1 Page 2037 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3013 4. CONNECT VSV FOR EVAP TO UPPER INTAKE MANIFOLD a. Install the accelerator cable clamp and VSV for the EVAP to the upper intake manifold. b. Connect the EVAP hose. c. Connect the VSV connector for the EVAP. 5. INSTALL THROTTLE BODY COVER BRACKET Install the throttle body cover bracket with the bolt. 6. INSTALL ACCELERATOR CABLE BRACKET a. Install the accelerator cable bracket with the 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the engine. 7. INSTALL FUEL PRESSURE PULSATION DAMPER 8. INSTALL INTAKE AIR CONNECTOR 9. INSTALL THROTTLE BODY COVER Page 1008 Fluid - Differential: Fluid Type Specifications Differential Fluid Front Grade ......................................................................................................................................... .............................................................. GL-5 or equivalent Viscosity ................................................. .......................................................................................................................................................... SAE 75W-90 Rear Grade .................................................................................................................... ................................................................................... GL-5 or equivalent Above -18° C (0° F) .......... .............................................................................................................................................................. ........................... SAE 90 Below -18° C (0° F) .................................................................................... ......................................................................................... SAE 85W-90 or 80W Page 1676 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 2611 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Page 6798 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 1865 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 6488 Driver Side J/B And Integration Relay Page 3604 Width 5.0 mm Thickness 3.2 mm 1-2 Shift Valve Height 16.5 mm Width 6.0 mm Thickness 3.2 mm Valve Body Check Ball Upper Valve Body Rubber Ball (A) Diameter 6.35 mm Rubber Ball (B) Diameter 5.45 mm Lower Valve Body Steel Diameter 6.35 mm Rubber Ball Diameter 5.45 mm Upper Valve Body x Lower Valve Body 6.45 Nm Detent Spring x Valve Body 10 Nm Valve Body x Transmission Case 10 Nm Oil Strainer x Valve Body 10 Nm Shift Solenoid Valve x Valve Body 10 Nm Spring Seat x Lower Valve Body 6.9 Nm Page 4183 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. ^ 09023-00100 6. REMOVE BRAKE,CALIPER AND DISC Page 1429 Part 4 of 4 Page 4435 Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL 1. REMOVE FRONT WHEEL Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT SPEED SENSOR CONNECTOR 3. REMOVE SPEED SENSOR (a) Remove the clips and 3 clamp bolts holding the sensor harness from the frame, upper arm and steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) (b) Remove the bolt and speed sensor from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check speed sensor signal. Locations Engine Room R/B Page 6863 Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 536 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Page 1579 Radiator: Service and Repair Removal and Installation Page 2761 CHART 16 CHART 17 Specifications Suspension And Axle - Lubricant Page 1918 CHART 10 Page 3364 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 4491 Wheel Speed Sensor: Diagrams Page 5884 a. Apply protective tape to the outer surface as shown in illustration, to keep the surface from being scratched. b. Using a heat light, heat the moulding to 20 - 30 °C (68- 86 °F). NOTE: Do not heat the moulding excessively. c. Using a scraper, pull off the roof drip side finish moulding from front end and rear end. HINT: Tape the scraper tip before use. 2. REMOVE MOULDING AND ADHESIVE a. Pull off the moulding by cutting the adhesive with a knife. b. Remove the moulding NOTE: Do not damage the body with the knife. INSTALLATION 1. CLEAN CONTACT SURFACE OF BODY a. Using a heat light, heat the body surface 40 - 60 °C (104 - 140 °F). NOTE: Do not heat the body excessively. b. Using a knife, cut away any rough areas on the body. NOTE: Be careful not to damage the body. c. Wipe off stains with cleaner. Page 2873 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 5905 Page 2261 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Testing and Inspection Tachometer: Testing and Inspection INSPECT TACHOMETER/ON-VEHICLE a. Connect a tune-up test tachometer, and start the engine. NOTE: - Reversing the connection of the tachometer will damage the transistors and diodes inside. - When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. b. Compare the tester and tachometer indications. DC 13.5 V 20°C at (77°F) INSPECT TACHOMETER RESISTANCE Measure the resistance between terminals with fixing pointer to the stopper. If resistance value is not as specified, replace the meter. Locations Engine Room R/B Engine Controls - Error When Reprogramming ECU Engine Control Module: All Technical Service Bulletins Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 1123 Driver Side J/B And Integration Relay Page 6797 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 4171 11. 4WD: Remove oil seal (inside). A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration above). B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. Remove axle hub from steering knuckle. A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. SST P/N: 09710-28012-01 (09710-07031) SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. Remove bearing from steering knuckle. Page 3892 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 30 12 - GROUND : Approx. 12 volts for 0.2 seconds with following operations - Door lock control SW unlocked - Door lock control SW looked with ignition key in cylinder and LH door open (Ignition key reminder function) - Door lock knob locked with ignition key in cylinder and LH door open. (Ignition key reminder function) - Unlocking the LH, RH door cylinder with key 13 - GROUND : Approx. 12 volts for 0.2 seconds with following operations - Door lock control SW locked - Locking the LH, RH door cylinder with key 14 - GROUND : Continuity with front LH door open (Standard cab) 14 - GROUND : Continuity with each LH door open (Access cab) 15 - GROUND : Continuity with front RH door open (Standard cab) 15 - GROUND : Continuity with each RH door open (Access cab) D16, D17 DOOR COURTESY SW FRONT LH, RH 1 - GROUND : Closed with door open D22, D23 DOOR KEY LOCK AND UNLOCK SW LH, RH 1 - 2 : Closed with door lock cylinder locked with key 3 - 2 : Closed with door lock cylinder unlocked with key D25, D26 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW LH, RH 4 - 1 : Closed with door lock knob UNLOCK position U1 UNLOCK WARNING SW 1 - 2 : Closed with key in cylinder Locations Hydraulic Control Assembly - Antilock Brakes: Locations Engine Compartment Ground Locations Transmission Mode Indicator - A/T: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 6875 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 497 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 5778 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3941 Step 3 Page 6089 Paint: Locations BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: 1. Anti-chipping paint should be applied to some areas before the second coat and to others after the top coat. 2. If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover. Page 3906 Glossary Of Terms And Symbols (Part 1) Page 4275 Wheel Cylinder: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 5908 Information PRELIMINARY INSPECTION INSTRUCTIONS Page 5156 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 2WD: INSTALL GREASE CAP 8. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Lightly strike the SST on its circumference evenly. b. Coat MP grease to the oil seal lip. Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 936 A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the accessory drive belt tensioner to release tension and remove the accessory drive belt. HINT: The pulley bolt for the belt tensioner has a left hand thread. B. Using the accessory drive belt routing label located on the passenger side of the radiator core support as a guide, install the new accessory drive belt. 2. Check belt tensioner operation. A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force. B. Ensure proper alignment of the belt with the ribbed grooves of each pulley. C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each pulley. D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see illustration). E. If the arrow mark falls outside area "A," the drive belt is incorrect. HINT: When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect. Page 3542 Torque Converter: Testing and Inspection INSPECTION 1. INSPECT ONE-WAY CLUTCH a. Install SST in the inner race of one-way clutch. SST 09350-30020 (09351-32010) b. Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-30020 (09351-32020) c. With the torque converter clutch standing on its side, check that the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the converter if the clutch still fails the test. 2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator, measure the drive plate runout. Maximum runout: 0.20 mm (0.0079 inch) If runout is not within the specification or if the ring gear is dam- aged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts. Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.) Page 3901 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3217 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 2975 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Page 2439 CHART 24 Page 1962 Page 4635 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation REMOVAL 1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. Page 848 5. As shown in the example chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Amount to turn adjusting cams (by graduation): Example: Front cam: 1.3 + Direction Rear cam: 3.3 + Direction d. Torque the front and/or rear adjusting cam set bolts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Page 2613 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Locations Page 4925 Glossary Of Terms And Symbols (Part 2) Page 3000 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop Pressure Drop Pressure Drop 1 Drop per 12 Minutes Page 3308 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 3529 Part 2 of 2 Page 6220 Cruise Control: Reading and Clearing Diagnostic Trouble Codes Clearing Diagnostic Trouble Codes NOTE: This is the only information provided by the manufacturer for Clearing Diagnostic Trouble Codes for this system. DTC CLEARANCE a. The following actions will erase DTCs and freeze frame data. 1. Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand-held tester to erase codes. (See the OBD II scan tool's instruction book for operating instructions.) 2. Disconnecting the battery terminals or EFI fuse. b. After completing repairs, the DTC retained in the memory can be cleared by removing the ECU-B fuse for 10 seconds or more with the ignition switch OFF. c. Check that the normal code is displayed after connecting the fuse. Displaying & Reading Trouble Codes NOTE: This is the only information provided by the manufacturer for reading diagnostic trouble codes for this system. 1. DIAGNOSIS SYSTEM a. Check the indicator. 1. Turn the ignition switch to ON. 2. Check that the CRUISE MAIN indicator light comes on when the cruise control main switch is turned ON, and that the indicator light goes off when the main switch is turned OFF. HINT: If the indicator check result is not normal, proceed to troubleshooting for the combination meter section. b. Check the DTC. HINT: If a malfunction occurs in the speed sensor or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and turns ON and OFF the CRUISE MAIN indicator light to inform the driver of a malfunction. At the same time, the malfunction is stored in memory as a diagnostic trouble code. Page 541 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 5495 Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to damage the webbing during repair. 3. Install the NEW tongue plate stopper A. Install a NEW tongue plate stopper in the hole of the webbing. NOTE Be sure to install the stopper in the correct direction as shown in the illustration. B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small "C" clamp. NOTE To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to moderate clamping force when crimping the two halves of the tongue plate stopper together. HINT Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel to each other. Page 5408 Clockspring Assembly / Spiral Cable: Service and Repair Removal and Installation Steering Wheel Pad And Spiral Cable REMOVAL 1. REMOVE STEERING WHEEL PAD 2. REMOVE STEERING WHEEL 3. REMOVE UPPER AND LOWER COLUMN COVERS 4. REMOVE SPIRAL CABLE INSTALLATION Page 2060 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Page 549 CHART 1 Page 1785 Glossary Of Terms And Symbols (Part 2) Collision / Non-Collision Inspections Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 395 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 2191 Crankshaft Position Sensor Page 223 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 4066 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. Page 6712 Brake Lamp: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 4697 Relay Box: Connector Views Engine Room R/B Page 864 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Air conditioning switched OFF 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Page 3359 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Electrical Specifications Resistance Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals with the switch ON (switch pin released). b. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 2559 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 1089 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1227 Intake: N = T + (A - 0.20 mm (0.008 inch)) Page 1908 Page 4223 Brake Rotor/Disc: Specifications FRONT BRAKE Standard thickness .............................................................................................................................. ................................................ 28.0 mm (1.102 in.) Minimum thickness ............................................. ............................................................................................................................... 26.0 mm (1.024 in.) Maximum disc runout .......................................................................................................................... ............................................. 0.07 mm (0.0028 in.) Page 6088 be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken paint. Page 3225 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Diagrams Front Door Window Glass: Diagrams Front Door (Part 1) Page 4169 A. Disconnect shock absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the 8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint. Specifications Wheel Cylinder: Specifications Wheel Cylinder Mounting Bolts 10 Nm Hydraulic Brake Line 15 Nm Page 1581 8. REMOVE RADIATOR ASSEMBLY Remove the 4 bolts and radiator assembly. 9. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No.1 fan shroud. DISASSEMBLY 1. REMOVE RADIATOR SUPPORTS Remove the 4 bolts, 2 pipes, 2 bushings and 2 radiator supports. 2. REMOVE RADIATOR CAP 3. REMOVE DRAIN PLUG 4. 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 diagram. b. While gripping the handle, adjust the stopper bolt so that dimension "B" shown in the diagram is 0.2 - 0.3 mm (0.008 - 0.012 inch). NOTICE: If this adjustment is not done, the claw may be damaged. 5. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230-01010 6. REMOVE TANKS AND O-RINGS Page 2365 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Page 3737 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 159 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Testing and Inspection Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Page 949 Page 2904 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2298 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 5541 Rear Seat Belt Extender Applications Page 2213 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 4208 32. Depress brake pedal several times. 33. Fill the brake reservoir with brake fluid and bleed brake system. 34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check). Repair Procedure No. 2 1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits. NOTE: It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. 2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on the rotor), replace the rotors using the service parts from the Parts Information table. 3. Check any new disc rotor for runout. 4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure. 5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts Information table. 6. Perform a road test. Page 6968 a. Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table. b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive as shown in the illustration. A: 8.0 mm (0.314 in.) B: 12.0 mm (0.472 in.) 8. INSTALL BACK WINDOW GLASS a. Position the glass so that the reference marks are lined up, and press in gently along the rim. b. Using a spatula, apply adhesive on the glass rim. c. Use a scraper to remove any excess or protruding adhesive. HINT: Confirm that the moulding is attached to the body panel as shown in the illustration. Page 688 Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under these conditions: 1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor. Page 2770 CHART 24 Page 6091 Page 5033 3. DISCONNECT UPPER BALL JOINT a. Remove the cotter pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the upper ball joint. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09958-04011) c. Support the steering knuckle securely. d. Remove the nut. 4. REMOVE REAR FENDER APRON SEAL Remove the 4 clips and rear fender apron seal. 5. REMOVE BRAKE AND FUEL LINE CLAMP Disengage the 2 brake lines and fuel line, and remove the nut and brake line clamp. 6. REMOVE UPPER SUSPENSION ARM Remove the nut, bolt, 2 washers and upper suspension arm. REPLACEMENT 1. REMOVE BUSHING a. Using a chisel and hammer, pry up the flange of the bushing. b. Using Special Service Tool (SST) and a press, remove the bushing. SST 09613-26010, 09631-20060, 09950-00020 Page 157 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 4658 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2095 Knock Sensor (Part 2) Page 4517 4. Press the NEXT soft key (if applicable) when the HELLO screen appears to proceed to the Main Menu. 5. Choose BATTERY TEST and press the SELECT soft key. 6. Select IN VEHICLE and press the NEXT soft key. 7. Select MODEL and press the NEXT soft key. NOTE: ^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad. ^ "MODEL" and "STOCK#" are linked to custom algorithms and are the most accurate testing procedures. Page 2291 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Locations Vapor Pressure Sensor Page 3432 Fluid Pump: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair. Page 5142 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber REMOVAL 1. SUPPORT BODY WITH SAFETY STANDS a. Jack up and support the body on safety stands. b. Lower the axle housing until the leaf spring tension is free, and keep it at this position. 2. REMOVE REAR WHEEL 3. REMOVE REAR SHOCK ABSORBER a. Remove the bolt and nut on the lower side of the shock absorber. b. While holding the piston rod, remove the nut, retainer, cushion and shock absorber. c. Remove the 2 retainers and cushion from the shock absorber. INSPECTION INSPECT SHOCK ABSORBER Page 4832 Page 6989 6. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim. NOTE: Do not touch the glass face after cleaning it. 7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M" Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTE: Let the primer coating dry for 3 minutes or more. - Do not coat Primer M to the adhesive. - Do not keep any of the opened Primer M for later use. 8. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G" a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. b. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTE: Page 3193 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Page 906 Timing Belt: Service and Repair Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. DISCONNECT CONNECTOR 3. RUN ENGINE AT APPROX. 2,000 rpm 4. SET BLOWER SPEED CONTROL SWITCH TO "HI" POSITION 5. SET TEMPERATURE CONTROL LEVER TO "MAX. COOL" POSITION 6. A/C SWITCH ON 7. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 4350 9. Remove steering knuckle. A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: Remove grease cap. A. Mount the axle hub in a soft jaw vise. NOTE: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). B. Using a screwdriver, remove the grease cap. NOTE: Be careful not to damage the grease cap. Page 3325 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 4092 Parts Information Page 5597 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 2642 Engine Control Module: Connector Views Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Page 4397 (b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the pistons when using compressed air. 3. REMOVE PISTON SEALS Using a screwdriver, remove the 4 piston seals from the cylinder. INSPECTION 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 inch) Minimum thickness: 26.0 mm (1.024 inch) Replace the disc if the thickness of the disc is at the minimum or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly. Service and Repair Front Fender Liner: Service and Repair FRONT FENDER APRON (ASSEMBLY) REMOVAL (WITH THE RADIATOR SUPPORT, COWL TOP SIDE PANEL (REMOVED.) Page 6083 least once a month to lubricate the compressor. 1. Turn off A/C and blower switches prior to starting engine. 2. Start and warm up the engine until engine idle drops below 1,000 rpm. 3. Turn on the A/C system (including the rear A/C) using the following settings: A. A/C Switch: On B. Blower Speed: High C. Engine Speed: Below 1,000 RPM 4. Keep A/C on with engine idling for at least one minute (in dual A/C vehicles leave on for two minutes). 5. Turn off A/C system and stop engine. Disk Brake Rotor Surface Rust Removal The brake rotors are made of cast iron so they may show gradual build-up of surface rust during long term storage. At least once every two months drive the vehicle and use the brakes normally stopping from about 30 mph at least 20 times. This regular usage will help prevent severe rust build up and the possibility of unwanted brake vibration concerns due to rust. NOTE ^ If the brake vibration still occurs after the braking cycle, determine the root cause of the brake vibration and repair. ^ Brake rotor resurfacing may be required if the rust was severe and resulted in excessive rotor thickness variation. Page 415 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1435 a. Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates aligned. If not, turn the crankshaft 1 revolution (360°). c. Remove the crankshaft pulley bolt. NOTICE: Do not turn the crankshaft pulley. 17. REMOVE TIMING BELT TENSIONER HINT: - When re-using timing belt: If the installation marks have disappeared, before remove the timing belt, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys. - When replacing timing belt tensioner only: To avoid meshing of the timing pulley and timing belt, secure one of them with string. And place matchmarks on the timing belt and RH camshaft timing pulley. Page 5993 Headliner: Diagrams Roof Headlining Component Locations Audible Warning Device Control Module: Component Locations Instrument Panel Page 4079 A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. 8. DISCONNECT LOWER BALL JOINT Page 3907 Glossary Of Terms And Symbols (Part 2) Page 1841 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Page 5087 Page 1437 24. REMOVE TIMING BELT GUIDE 25. REMOVE TIMING BELT COVER SPACER 26. REMOVE TIMING BELT HINT: If re-using the belt and the installation mark has disappeared from it, place a new installation mark on the timing belt to the match the dot mark of the crankshaft timing pulley. 27. REMOVE NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY a. Using a 10 mm hexagon wrench, remove the bolt, No.1 idler pulley and plate washer. b. Remove the bolt and No.2 idler pulley. 28. REMOVE CRANKSHAFT TIMING PULLEY Using SST, remove the timing pulley. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) NOTICE: Do not turn the timing pulley. INSPECTION Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Gauge: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Component Locations Stop Light System Page 908 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. REMOVE RADIATOR ASSEMBLY 4. REMOVE THROTTLE BODY COVER 5. REMOVE INTAKE AIR CONNECTOR ASSEMBLY Page 4354 21. 4WD: Using the following SSTs and a press, install the bearing spacer. SST P/N: 09950-60010 (09951-00650) SST P/N: 09950-70010 (09951-07150) 22. 4WD: Install new oil seal (inside). A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). SST P/N: 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. Install steering knuckle. A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. Connect the lower ball joint to the steering knuckle with 4 bolts. Electrical Specifications Resistance Service and Repair Tape Player: Service and Repair Tape player/head cleaning MAINTENANCE a. Raise the cassette door with your finger. Next, using a pencil or similar object, push in the guide. b. Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans. Testing and Inspection Power Window Circuit Breaker: Testing and Inspection Driver's Door INSPECT POWER WINDOW MOTOR CIRCUIT BREAKER OPERATION a. Disconnect the connector from the master switch. b. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 4 on the wire harness side connector and raise the window to fully closed position. c. Continue to apply voltage, check that a circuit breaker operation noise is heard within approximately 4 to 40 seconds. d. Reverse the polarity, check that the window begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. Passenger's Door INSPECT POWER WINDOW MOTOR CIRCUIT BREAKER OPERATION a. Disconnect the connector from the power window switch. b. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 1 on the wire harness side connector, and raise the window to fully closed position. Page 7029 b. Connect terminals 1 and 5. c. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. Page 1576 Part 2 of 2 Engine - Accessory Drive Belt Squealing Noise Drive Belt: Customer Interest Engine - Accessory Drive Belt Squealing Noise ENGINE EG026-06 REVISED Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '06 Tundra April 21, 2006 TSB REVISION NOTICE: ^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered. Previous versions of this TSB should be discarded. Introduction Some customers may experience an abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor bracket, and revised installation procedure have been developed to address this condition. Applicable Vehicles ^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Parts Information Warranty Information Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 3447 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 155 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 6345 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 6773 Fog/Driving Lamp Relay: Testing and Inspection INSPECT FOG LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 4024 HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2 seconds. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Loosen the lock nut. (b) Adjust the length of the shackle No. 2. Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch) Adjustment range: 112 - 128 mm (4.41 - 5.04 inch) HINT: One turn of the nut changes the fluid pressure as shown in the following specification. 7.4 kPa (0.76 kgf/cm, 11 psi) (c) Torque the lock nut. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body. Low pressure-Lower body High pressure-Raise body (e) Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be adjusted, inspect the valve body. 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with the load sensing spring or move it. Page 3219 Transmission Mode Indicator - A/T: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 5836 Rear Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Page 6256 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 4597 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1031 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE engine: Remove the air cleaner assembly. b. 2UZ-FE engine: Remove the air cleaner assembly with air cleaner hose. c. Disconnect the pressure feed tube from the PS vane pump. d. Connect Special Service Tool (SST), as shown in the illustration. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check that the valve of the SST is in the open position. e. Bleed the power steering system. f. Start the engine and run it at idle. g. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) h. With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: ^ Do not keep the valve closed for more than 10 seconds. ^ Do not let the fluid temperature become too high. i. With the engine idling, open the valve fully. Page 2443 Page 2218 Data Link Connector: Testing and Inspection Check 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. HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the OBD II scan tool or TOYOTA hand-held tester to the DLC3, turn the ignition switch ON and operate 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. Electrical Specifications Resistance Testing and Inspection Vanity Lamp: Testing and Inspection INSPECT VANITY LIGHT CONTINUITY If continuity is not as specified, replace the bulb or vanity light. Page 5631 c. Install the SST. 1. Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082-00700,09082-00740 NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. 2. Place the front seat outer belt on the ground and cover it with the disc wheel with tire. NOTE: Place the front seat outer belt as shown in the illustration. 3. Move the SST at least 10 m (33 ft) away from the disc wheel. NOTE: Take care not to damage the SST wire harness. d. Activate the seat belt pretensioner. 1. Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel. 3. Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. Locations Relay Box: Locations Driver Side J/B And Integration Relay Page 856 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 258 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Page 6731 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 257 Brakes - Front Brakes Vibrating Technical Service Bulletin # BR004R-02 Date: 040305 Brakes - Front Brakes Vibrating BRAKES BR004-02 REVISED September 16, 2002 Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra TSB REVISION NOTICE: ^ March 5, 2004: A torque specification in, step 24, was changed. ^ September 8, 2003: A torque specification in, step 28, was changed. The previous TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles ^ 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 6562 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4989 c. Deploy the airbag. 1. Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. 2. Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. d. Dispose of steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. 2. When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. Deployment When Disposing of Steering Wheel Pad DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a front passenger airbag assembly, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a front passenger airbag assembly which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - 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 an airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. - The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. DISPOSE HORN BUTTON ASSY(WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT METHOD)[45130/ 98-75] NOTE: - When disposing of the steering wheel pad (with air- bag) only, never use the customers vehicle to deploy the airbag. - Be sure to follow the procedure given below when deploying the airbag. Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Page 2182 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 1963 Engine Bank Identification Page 70 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Engine Controls - Error When Reprogramming ECU Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Service Data Connecting Rod: Specifications Service Data Connecting Rod Thrust Clearance Standard ....................................................................................... .............................................................................................................. 0.160 - 0.290 mm Maximum . .............................................................................................................................................................. .................................................. 0.35 mm Connecting Rod Thickness .................................................................................................................. .................................................. 22.880 - 22.920 mm Connecting Rod Big End Inside Diameter Mark 1 ............................................................................... ..................................................................................................................... 55.000 - 55.006 mm Mark 2 .................................................................................................................................................. .................................................. 55.006 - 55.012 mm Mark 3 ............................................................. ....................................................................................................................................... 55.012 55.018 mm Mark 4 ............................................................................................................................... ..................................................................... 55.018 - 55.024 mm Connecting Rod Alignment Maximum Bend ........................................................................................ ............................................................................................ 0.05 mm per 100 mm Maximum Twist ... .............................................................................................................................................................. ................. 0.15 mm per 100 mm Connecting Rod Bolt Standard Diameter ............................................................................................ ......................................................................................... 7.200 - 7.300 mm Minimum Diameter ....... .............................................................................................................................................................. ............................. 7.00 mm Connecting Rod Cap Bolts Torque ...................................................................................................... ................................................................................................................ 24.5 Nm Page 5558 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 4083 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. ^ 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. ^ 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Page 6334 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 5072 Page 2473 Engine Controls - Error When Reprogramming ECU Engine Control Module: All Technical Service Bulletins Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Page 5986 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Page 2069 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 5917 Page 5354 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Ground Locations Transmission Mode Indicator - A/T: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 1746 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Page 6309 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 2362 Knock Sensor (Part 2) Page 2849 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Page 548 O2S Application Table O2S Failure Threshold Charts Page 5369 Supplemental Restraint System Page 2034 Glossary Of Terms And Symbols (Part 1) Page 3613 HINT: During reassembly please refer to the spring specifications to help you to discriminate between the different springs. Spring Retainer 3. CHECK BALL Page 5284 4. Cycle the temperature control knob several times and confirm proper water control valve adjustment. Page 6951 c. Continue to apply voltage, check that circuit breaker operation noise is heard within approximately 4 to 40 seconds. d. Reverse the polarity, check that the window begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. Page 773 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 849 Measuring Point Reference 5. INSPECT TOE-IN If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN AND WHEEL ANGLE a. Remove the 2 clips. b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount 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 end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Removal and Installation Heater Core Case: Service and Repair Removal and Installation Heater Unit REMOVAL 1. REMOVE COOLING UNIT 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. Page 6565 Seat Belt Reminder Lamp: Electrical Diagrams Key Reminder And Seat Belt Warning Service Hints KEY REMINDER AND SEAT BELT WARNING Page 6673 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Front Differential Seals and Gaskets: Service and Repair Front Differential REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. DRAIN DIFFERENTIAL OIL 3. REMOVE FRONT PROPELLER SHAFT 4. REMOVE COMPANION FLANGE a. Using a chisel and hammer, loosen the staked part of the nut. b. Using Special Service Tool (SST) to hold the flange, remove the nut. SST 09330-00021 c. Using SST, remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) Page 1129 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system/components or in the powertrain control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the DTCs remain recorded in the ECM memory. Page 4601 Auxiliary Power Outlet: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4674 Driver Side J/B And Integration Relay Page 3358 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 1780 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Front Seat Cover - Damaged Seat Cover: All Technical Service Bulletins Front Seat Cover - Damaged BODY BO006-02 Title: FRONT SEAT COVER DAMAGE Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats March 1, 2002 Introduction Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could potentially wear a hole into the seat cover material during entry and exit of the vehicle. This condition has been addressed and corrected in production. The instructions below will illustrate how to properly repair vehicles with this condition. Applicable Vehicles 2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN shown below. 2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN shown below. Production Change Information Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Page 5525 Seat Belt Page 1790 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5395 Clockspring Assembly / Spiral Cable: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. Page 2750 O2S Application Table O2S Failure Threshold Charts Page 3281 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Page 6531 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5390 Supplemental Restraint System Page 2810 CHART 2 CHART 3 CHART 4 Page 731 Knock Sensor (Part 2) Page 5577 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1364 Engine Oil Pressure: Testing and Inspection INSPECTION 1. 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: Use API SJ, Energy-Conserving or ILSAC multi-grade engine oil. SAE 5W-30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 2. CHECK ENGINE OIL LEVEL The oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and add oil up to the "F" mark. NOTICE: Do not fill with engine oil above the "F" mark. 3. REMOVE ENGINE UNDER COVER 4. REMOVE OIL PRESSURE SWITCH 5. INSTALL OIL PRESSURE GAUGE 6. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 7. CHECK OIL PRESSURE Oil pressure: 8. REMOVE OIL PRESSURE GAUGE 9. REINSTALL OIL PRESSURE SWITCH a. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Reinstall the oil pressure switch. 10. START ENGINE, AND CHECK FOR ENGINE OIL LEAKS Page 4564 Using vernier calipers, measure the commutator diameter. Standard diameter Minimum diameter If the diameter is less than minimum, replace the armature. 6. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. Diagram Information and Instructions Seat Belt Reminder Buzzer: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Locations Relay Box: Locations Driver Side J/B And Integration Relay ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2732 Engine Bank Identification Page 4911 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 3682 Page 4836 Page 5055 - Length: 6 in. ^ Ratcheting tie down strap (quantity 1) - Minimum Width & Length: 1 in. x 6 ft. ^ Bicycle Cable Lock (quantity 1) - Minimum Width & Length: 3/8 in. x 5 ft. - Built-in lock with key - Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent IV. Background On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame cross-member. In the worst case the spare tire stowed under the truck bed may become separated from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or associated brake lines. Page 3313 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 2041 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2475 Page 6323 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2076 Camshaft Position Sensor Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 5442 SRS Warning Light: Description and Operation SRS WARNING LIGHT The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly self-diagnosis. In normal operation conditions when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes off. Page 5647 Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG MANUAL ON-OFF SWITCH Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the passenger airbag manual on-0ff switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the front passenger airbag is disabled, OFF indicator inside the switch will light up. Page 4638 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5230 7. DISCONNECT LIQUID TUBE AND DISCHARGE HOSE Remove the 2 bolts and disconnect the both tube and hose. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Cap open the fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tubes. 8. REMOVE CONDENSER a. Remove the 2 bolts and 2 lower brackets. b. Remove the 4 bolts and 2 upper brackets. c. Pull the condenser forward and pull it upward. HINT: At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the compressor. Add 40 - 50 cc (1.4 - 1.7 fl.oz.) Compressor oil: ND-OIL 8 or equivalent INSTALLATION Installation is in the reverse order of removal. Testing and Inspection Power Door Lock Actuator: Testing and Inspection INSPECT DOOR KEY LOCK MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 2, and check that the door lock link moves to UNLOCK position. b. Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. Diagram Information and Instructions Relay Box: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 5407 - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN COLLISION Dispose of the steering wheel pad (with airbag). CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Description and Operation Brake Fluid Solenoid Valve Relay: Description and Operation ABS Solenoid Relay This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. Page 547 Page 3799 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Page 2823 CHART 21 Page 2819 CHART 16 CHART 17 Page 4316 Repair Procedure 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. Page 152 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 577 CHART 30 Page 4595 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 211 Page 811 a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4 switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and the 4HI indicator lights come on when the touch select high-low switch is in OFF position. HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position. - If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash. 3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals. Touch select 2-4 switch Touch select high-low switch: If continuity is not as specified, replace the center integration panel assembly. 4. INSPECT ACTUATOR RESISTANCE a. Using an ohmmeter, measure the resistance between terminals 1 and 2. Standard resistance: 0.3 - 100 Ohms b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground. Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the actuator assembly. Page 1593 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Exhaust System - Sulfur Smell Fuel: Technical Service Bulletins Exhaust System - Sulfur Smell ENGINE EG003-03 February 24, 2003 Title: SULFUR ODOR FROM EXHAUST Models: All Models Introduction Some owners of Toyota vehicles may experience a sulfur-like or "rotten egg" odor from the exhaust system. Sulfur is a natural component of crude oil from which gasoline is refined and the amount of sulfur can be decreased through the refining process. The amount of sulfur in fuel sold in California is regulated, however gasoline sold in other states can have substantially higher sulfur content. Sulfur content also varies considerably between gasoline brands and locations. Applicable Vehicles ^ All Models. Repair Procedure A sulfur odor emitted from the vehicle's tailpipe does not necessarily indicate that there is an issue with the engine's running condition, but is most likely directly related to the fuel. ^ If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed: ^ If the MIL light is ON, check for DTCs and repair as necessary. If no trouble is found after performing the above check, recommend the customer try a different source of fuel. Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will therefore not be considered warrantable. Warranty Information Page 6272 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 1939 CHART 28 Page 6709 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Locations Specifications Fuel Tank And Line Testing and Inspection Seat Belt Buckle Switch: Testing and Inspection Bench Type and Passenger Side: INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. (w/o Bench Type (Driver Side): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 3 and 4 on the switch side connector with the switch ON (elt fastened). b. Check that no continuity exists between terminal 3 an 4 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. Separate Type (w/ Power Seat): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner. Page 6586 Key Reminder Switch: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 2277 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 583 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Page 3706 b. Using SST to hold the flange, remove the nut and spacer. SST 09330-00021 c. Place matchmarks on the flange and shaft. d. Using SST, remove the flange from the intermediate shaft. SST 09950-30011 (09951-03010, 09953 -03010, 09954-03010, 09955-03030, 09956-03020) e. Remove the spacer and center support bearing from the intermediate shaft. INSPECTION NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. INSPECT PROPELLER SHAFT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT Using a dial indicator, check the runout of shafts. Maximum runout: 0.8 mm (0.031 inch) If shaft runout is greater than the maximum, replace the shaft. 2. INSPECT SPIDER BEARING a. Inspect the spider bearing for wear or damage. b. Using a dial indicator, check the spider bearing axial play by turning the yoke of flange while holding the shaft tightly. Maximum bearing axial play: Front propeller shaft: 0.05 mm (0.0020 inch) Rear propeller shaft: 0 mm (0 inch) If the spider bearing axial play exceeds the maximum, replace the spider bearing. Page 4636 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 1571 Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. w/ Tachometer Page 6322 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4974 Steering Wheel: Description and Operation STEERING WHEEL PAD (with AIRBAG) The inflater and bag of the SRS are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge, gas generant, etc., and inflates the bag when instructed by the airbag sensor assembly. Page 4838 a. Loosen the front and/or rear adjusting cam set bolts. b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. c. How to read adjustment chart (Example). 1. Find the applicable wheel alignment standard value for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10'(0.17°) Caster: 3°00' 3. Measure the present wheel alignment value with the vehicle in non-loaded condition. 4. Mark the measured present value on the adjustment chart. Example: Camber: 0°30'(0.50°) Caster: 2°40'(2.67°) Page 2814 CHART 10 Engine Controls - Error When Reprogramming ECU Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Page 1743 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 6261 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 6315 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 3101 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 5. REMOVE THROTTLE BODY a. Disconnect the throttle position sensor connector. b. Disconnect the throttle control motor connector. c. Disconnect the accelerator pedal position sensor connector. d. Disconnect the accelerator pedal position sensor wire from the 2 clamps on the wire brackets. e. Disconnect the PCV hose and water bypass hose from the throttle body. f. Remove the ventilation cap. g. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. h. Disconnect the water bypass hose from the manifold thermostat on the throttle body, and remove the throttle body. i. Remove the gasket. INSTALLATION 1. INSTALL THROTTLE BODY a. Connect the water bypass hose to the manifold thermostat on the throttle body. Page 4234 Required SSTs Repair Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember with a foot PKB (on an automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click" and then press the PKB pedal a second time so it will disengage when it is released. At this time, the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step C, then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Proceed to the Repair Procedures that follow. F. If no vibration is felt during step C, then the front brake assemblies are the cause of brake vibration on this vehicle. Refer to TSB No. BR004-02, "Front Brake Vibration," for parts and repair information relating to Tundra front brake vibration. 3. Measure the rear axle shaft centering area diameter. If the measured value deviates from the standard (105.946 - 106 mm [4.171 - 4.173 in.]), replace the rear axle shaft (Standard: Refer to Figure 1). Ground Locations Audible Warning Device: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 5346 - Standard cab: Check for deformation of the quarter panel. - Access cab: Check for deformation of the ELR bracket. - Check for cuts and minute cracks in wire harness or marked discoloration on the front seat outer belt. CAUTION: Be sure to follow the correct procedure, for removal and installation of the front seat outer belt. 2. PRETENSIONER IS ACTIVATED a. Perform a diagnostic system check. * Page 4599 Glossary Of Terms And Symbols (Part 1) Page 846 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). INSPECTION 1. MEASURE VEHICLE HEIGHT Measuring points: A: Ground clearance of the front drive shaft center B: Ground clearance of the front adjusting cam bolt center C: Ground clearance of the leaf spring front side bushing center D: Ground clearance of the rear axle shaft center Vehicle height: Front: A - B Rear: C - D NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle 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 operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ...................................................... 1,324 kPa or More Minimum Pressure ......................................... ........................................................................................................................................................... 981 kPa Difference Between Each Cylinder ........................................................................................ ......................................................................... 98 kPa or Less Page 1766 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Page 6589 Splice Location B11 Page 1387 Oil Pressure Gauge: Testing and Inspection INSPECT OIL PRESSURE GAUGE RESISTANCE Measure the resistance between terminals A and B. If resistance value is not as specified, replace the receiver gauge. Locations Windshield Wiper Blade - Maintenance and Cleaning Wiper Blade: Technical Service Bulletins Windshield Wiper Blade - Maintenance and Cleaning BODY BO030-01 Title: WINDSHIELD WIPER BLADE MAINTENANCE AND CLEANING Models: All Models December 7, 2001 Introduction The following procedures are recommended to maintain windshield wiper blade performance. Applicable Vehicles ^ All models. Warranty Information Maintenance, Cleaning and Use Recommendations for Windshield Wiper Maintenance, Cleaning and Use: 1. Scheduled Maintenance ^ Check wiper rubber blades every 4 - 6 months or 7,500 miles for wear, cracking and contamination. ^ Clean glass and rubber wiper blades if blades are not clearing glass adequately. If this does not correct the problem, then replace the rubber elements. 2. Cleaning Procedure ^ Wiper Rubber: Bugs, dirt, sap and road grime on blades will cause streaking. ^ Clean wiper rubber of road and environmental debris using cloth or paper towel soaked with windshield washer fluid or mild detergent. ^8DO NOT USE fuel, kerosene, or petroleum based products to clean rubber wiper blades. ^ Windshield: Bugs, road grime, sap and car wash wax treatments decrease wiper performance. ^ Rinse windshield with water and apply non-abrasive cleaner, such as Bon-Ami (www.faultless.com), with a sponge. NOTE: Make sure to use plenty of water with all powder based cleaners so the glass is not scratched. 3. Contributors to Poor Performance/Decreased Rubber Blade Life (require rubber replacement) ^ Dusty areas cause the rubber edge to wear quickly. ^ Sand and salt used for road conditioning during winter causes the edge to wear quickly, so areas with significant snowfall require more frequent wiper replacement. ^ Heat and time cause the rubber to become excessively "permanent set," so the rubber does not turn over, resulting in streaking and/or unwiped areas on the glass. ^ Rubber is easily cut or torn while using ice scrapers on the glass. ^ Rubber can be torn when pulling blades off a frozen windshield. Page 4528 c. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: 12.5 - 12.9 V at 20 °C (68 °F) If the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES a. Check that the battery terminals are not loose or corroded. b. Check the fusible link and fuses for continuity. Page 6551 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 6284 Audible Warning Device Control Module: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 4578 a. 1.4 kW type: Remove the 2 bolts. Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) b. 2.0 kW type: Remove the 2 screws. Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf) c. Remove the starter housing, return spring, idler gear, bearing and starter clutch assembly. HINT: At the time of assembly, please refer to the following item. Apply grease to the return spring and insert the return spring into the clutch shaft hole. 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. HINT: At the time of assembly, please refer to the following item. Apply grease to the steel ball and insert the steel ball into the clutch shaft hole. 5. REMOVE BRUSH HOLDER a. Remove the 2 screws w/ O-ring and end cover from the field frame. Torque: 1.4 kW type : 1.5 N.m (15 kgf.cm, 13 in.lbf) 2.0 kW type : 3.8 N.m (39 kgf.cm, 34 in.lbf) b. Remove the O-ring from the field frame. Page 3240 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3678 The design of the rear axle seal has been changed from a flat face to an angled face for part number 90310-50006 and part number 90310-56002. Installation Procedure Sequoia To properly install Rear Axle Oil Seal part number 90310-56002, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00730-01) - Replacer 73 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Tacoma & Tundra To properly install Rear Axle Oil Seal part number 90310-56006, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00710) - Replacer 71 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Page 968 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Diagrams Access Door Page 1716 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 6265 Glossary Of Terms And Symbols (Part 2) Page 870 e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time. 4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away. 5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag. g. Observe these precautions when connecting the fuel tube connector (quick type): 1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe. Page 6832 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 742 Air Bag Deactivation Switch: Testing and Inspection PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off switch connector on the airbag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 558 CHART 15 Page 1530 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 6523 Glossary Of Terms And Symbols (Part 1) Page 6507 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 5247 8. REMOVE HEATER CONTROL ASSEMBLY Remove the heater control assembly, then disconnect the connectors. INSTALLATION 1. INSTALL HEATER CONTROL ASSEMBLY a. Connect the connectors. b. Pass the heater control as shown in the illustration. c. When using the removed one: Install the heater control assembly. d. When using a new one: Install the heater control assembly. 2. ADJUST HEATER CONTROL CABLES a. Set the mode control dial at "FACE" position. Page 6554 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1016 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Grade ................................................................................................................................................... ............................................................ GL-4 or GL-5 Viscosity ........................................................... ................................................................................................................................................ SAE 75W-90 Page 423 d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the buzzer stops sounding. If operation is not as specified, replace the combination meter. 4. INSPECT COMBINATION METER CIRCUIT Page 3561 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 2454 Applicable Vehicles Page 2617 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 200 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 705 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 5811 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5578 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2343 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 6683 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 125 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Electrical - SRS And HV Wiring Repairs Wiring Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 4190 Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. ^ 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 6293 12 - GROUND : Approx. 12 volts for 0.2 seconds with following operations - Door lock control SW unlocked - Door lock control SW looked with ignition key in cylinder and LH door open (Ignition key reminder function) - Door lock knob locked with ignition key in cylinder and LH door open. (Ignition key reminder function) - Unlocking the LH, RH door cylinder with key 13 - GROUND : Approx. 12 volts for 0.2 seconds with following operations - Door lock control SW locked - Locking the LH, RH door cylinder with key 14 - GROUND : Continuity with front LH door open (Standard cab) 14 - GROUND : Continuity with each LH door open (Access cab) 15 - GROUND : Continuity with front RH door open (Standard cab) 15 - GROUND : Continuity with each RH door open (Access cab) D16, D17 DOOR COURTESY SW FRONT LH, RH 1 - GROUND : Closed with door open D22, D23 DOOR KEY LOCK AND UNLOCK SW LH, RH 1 - 2 : Closed with door lock cylinder locked with key 3 - 2 : Closed with door lock cylinder unlocked with key D25, D26 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW LH, RH 4 - 1 : Closed with door lock knob UNLOCK position U1 UNLOCK WARNING SW 1 - 2 : Closed with key in cylinder Page 2744 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Diagram Information and Instructions Transmission Mode Indicator - A/T: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 5630 3. Move the SST to at least 10 m (33 ft) away from the front of the vehicle. 4. Close all the doors and windows of the vehicle. NOTE: Take care not to damage the SST wire harness. 5. Connect the SST red clip to the battery 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) area around of the vehicle. 2. Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. f. Dispose of front seat outer belt (with seat belt pretensioner). CAUTION: The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. - Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner. HINT: When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with activated front seat outer belt still installed. 2. ACTIVATION WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY NOTE: When disposing of the front seat outer belt (with seat belt pretensioner) only, never use the customer's vehicle to activate the seat belt pretensioner. - Be sure to follow the procedure given when activating the seat belt pretensioner. HINT: Have a battery ready as the power source when activating the seat belt pretensioner. a. Remove the front seat outer belt. HINT: Cut the belt near the seat belt retractor. b. Check the functioning of SST. (See step 1-(a)) SST 09082-00700,09082-00740 Page 26 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 4751 Fuse Block: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6232 Terminals Of ECM - View/Pinouts Page 5096 Seat Belts - Shoulder Belt Particle (Dirt) Buildup Seat Belt: Customer Interest Seat Belts - Shoulder Belt Particle (Dirt) Buildup BODY BO019-01 August 10, 2001 Title: SHOULDER BELT ANCHOR TAPE SET Models: All Applicable Models Introduction To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor, the following procedure has been developed. Applicable Vehicles ^ 1996-2001 model year 4Runner*1 vehicles. ^ 1996-2001 model year Land Cruiser vehicles. ^ 1996-2001 model year RAV4*2 vehicles. ^ 2001 model year Sequoia vehicles. ^ 1996-1998 model year T100 trucks. ^ 1996-2001 model year Tacoma*1 trucks. ^ 2000-2001 model year Tundra trucks. *1 Except rear seat belt. *2 Except rear seat belt of soft top models. Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Installation Procedure 1. CLEAN SHOULDER BELT ANCHOR NOTE: ^ Do not install the tape when the vehicle temperature is below the freezing point. ^ Do not re-use removed fluorocarbon resin tape. Page 2209 Glossary Of Terms And Symbols (Part 2) Page 2010 Oxygen Sensor: Description and Operation Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Page 2134 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Ground Locations Seat Belt Reminder Lamp: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2045 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 1987 CHART 16 CHART 17 Page 5180 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 2522 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 845 Page 4064 ^ 09023-00100 6. REMOVE BRAKE CALIPER AND DISC A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. Page 2241 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 6803 Horn: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 6230 Wiring Diagram Page 4337 Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). ^ 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Page 4861 Steering - Lubricant Page 6353 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2620 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. A/C - Insufficient Cabin Cooling Heater Control Valve: All Technical Service Bulletins A/C - Insufficient Cabin Cooling HEATING & AIR CONDITIONING AC004-04 May 20, 2004 Title: POOR PERFORMANCE OF A/C SYSTEM Models: '01 - '04 Sequoia & '00 - '04 Tundra May 20, 2004 Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to correct the condition. Applicable ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change Effective VINs shown below. ^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 3875 STANDARD VALUE OF ECU TERMINAL Page 6270 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Brakes - Vibration From Front Brakes Technical Service Bulletin # BR004R-02 Date: 040924 Brakes - Vibration From Front Brakes BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra September 16, 2002 TSB REVISION NOTICE: ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque speification, step 24, was changed. ^ September 8, 2003: A torque specification, step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 5603 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminals and the switch body with the switch ON (switch pin released: opened door). b. Check that no continuity exists between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. Page 71 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2842 Oxygen Sensor: Description and Operation Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Specifications Crankshaft Main Bearing: Specifications Main Bearing Cap Bolt Standard Diameter ......................................................................................... ........................................................................................ 10.760 - 10.970 mm Minimum Diameter .... .............................................................................................................................................................. .............................. 10.40 mm Tightening Torque Step 1 .................................................................................................................... ...................................................................................................... 27 Nm Step 2 ................................ .............................................................................................................................................................. ... Additional 90 degrees Page 1093 Driver Side J/B And Integration Relay Page 551 CHART 5 CHART 6 Page 6178 b. Using a torx socket wrench (T40), remove the 4 screws and 2 tailgate hinges from the tailgate. INSTALLATION 1. INSTALL TAILGATE a. Using a torx socket wrench, install the tailgate hinges with the 4 torx screws to the tailgate. Torque: 17 N.m (178 kgf.cm, 13 ft.lbf) b. Install the tailgate with the 2 bolts to the body. Torque: 17 N.m (178 kgf.cm, 13 ft.lbf) NOTE: Be careful not to drop the tailgate. 2. INSTALL TAILGATE CABLE a. Install the tailgate cable and gate side shaft to the tailgate. Torque: 26 N.m (270 kgf.cm, 20 ft.lbf) b. Install the tailgate cable and deck side shaft to the body. Torque: 26 N.m (270 kgf.cm, 20 ft.lbf) c. Employ the same manner described above to the other side. 3. INSTALL TAILGATE LOCK STRIKER Using a torx socket wrench, install the 2 tailgate lock strikers with the 4 torx screws. Page 3158 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Specifications Thermostat: Specifications Valve Opening Temperature 80 - 84 deg C Valve Lift 10 mm at 95 deg C or More Page 6012 Wireless Transmitter Identification Page 3603 Total No. Of Coils 10.83 1-2 Shift Valve Purple Free Length 30.77 mm Coil Outer Diameter 9.7 mm Total No. Of Coils 8.5 Check Valve Free Length 20.45 mm Coil Outer Diameter 6.6 mm Total No. Of Coils 8.73 Valve Body Key Upper Valve Body Lock-Up Valve Height 14.00 mm Width 5.00 mm Thickness 3.2 mm Secondary Regulator Valve Height 10.0 mm Width 5.00 mm Thickness 3.2 mm 3-4 Shift Valve Height 16.5 mm Width 6.00 mm Thickness 3.2 mm 2-3 Shift Valve Height 14.00 mm Width 5.00 mm Thickness 3.2 mm 2nd Coast Modulator Valve Height 16.5 mm Width 6.00 mm Thickness 3.2 mm Low Coast Modulator Valve Height 25.0 mm Width 4.0 mm Lower Valve Body Primary Regulator Valve Height 14.5 mm Thickness 3.2 mm Cut Back Valve Height 6.0 mm Width 6.0 mm Thickness 3.2 mm Solenoid Modulator Valve Height 25.0 mm Width 4.0 mm Accumulator Control Valve Height 12.5 mm Page 2636 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4721 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 4735 Driver Side J/B And Integration Relay Fuse Applications (Part 2) Driver Side J/B And Integration Relay Fuse Applications (Part 3) Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for no more than 5 - 10 seconds at a time. If the spark does not occur, do the test as per the given flow chart. 7. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) 8. Reinstall the ignition coils (with igniter). Page 3632 Maximum clearance: 0.35 mm (0.0138 inch) If the clearance exceeds the maximum, replace the fork or sleeve. Brakes - Vibration From Rear Brake Drum: Customer Interest Brakes - Vibration From Rear BRAKES BR001-01 January 12, 2001 Title: REAR BRAKE VIBRATION Models: '00 - '01 Tundra TSB Update Notice: The information contained in this TSB updates BR006-00, dated November 17, 2000. Revised text is underlined. New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the star wheel adjuster has been reduced from 30 to 26 teeth. Applicable Vehicles ^ 2000 - 2001 model year Tundra vehicles. Production Change Information Parts Information Repair Procedure 1. Grind rear brake drums with brake lathe to within serviceable limits. 2. If the drums are unserviceable or above maximum inside diameter, replace the drums. 3. If there is uneven wear on the lining, replace the left and right brake shoes. 4. Replace the parking brake shoe strut sets. 5. Adjust the parking brake to specifications. 6. Reinstall the rear wheels, and torque wheel nuts to: Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf) 7. Road test. Warranty Information Page 2762 CHART 18 CHART 19 Page 3660 8. REMOVE DRIVE SHAFT a. Right-Hand drive shaft: Using a brass bar and hammer, remove the Right-Hand drive shaft. NOTICE: Be careful not to damage the dust cover and oil seal. b. Left-Hand drive shaft: Using SST, remove the Left-Hand drive shaft. SST 09520-01010, 09520-24010 (09520-32040) NOTICE: Be careful not to damage the dust cover and oil seal. c. Using a screwdriver, remove the snap ring from the inboard joint shaft. INSTALLATION 1. INSTALL DRIVE SHAFT TO DIFFERENTIAL a. Install a new snap ring to the inboard joint shaft. b. Coat the gear oil to the inboard joint shaft and differential case sliding surface. c. Set the snap ring with opening side facing downward. d. Using a brass bar and hammer, install the drive shaft. NOTICE: Be careful not to damage the dust cover and oil seal. HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feeling when driving it in. e. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in the axial direction. f. Check that the drive shaft cannot be removed by hand. 2. Left-Hand drive shaft: INSTALL LEFT-HAND SHOCK ABSORBER 3. CONNECT DRIVE SHAFT TO STEERING KNUCKLE NOTICE: Be careful not to damage the oil seal, boots and dust seal. 4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT a. Connect the lower suspension arm to the lower ball joint. b. Install the nut and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. HINT: Face the hole for the cotter pin forward. Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) 5. INSTALL DRIVE SHAFT LOCK NUT a. While applying brakes, install the nut. Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.) b. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Page 1531 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Page 2031 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Testing and Inspection Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Page 4581 Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate. c. Remove terminal kit parts. 1. Using SST, loosen the terminal nuts. SST 09810-38140 2. Terminal C Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside). 3. Terminal 30 Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper. d. Install new terminal 30 kit parts. 1. Temporarily install a new terminal insulator (inside). 2. Temporarily install a new contact plate. 3. Temporarily install a new terminal bolt. 4. Temporarily install a new O-ring. 5. Temporarily install a new packing and new terminal insulator (outside). Install a new packing to a new terminal insulator, and install them. HINT: Match the protrusion of the insulator with the indentation of the housing. 6. Temporarily install a new wave washer. 7. Temporarily install a new terminal nut. NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction. Page 959 2. Tighten the union bolt by hand. 3. Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. Page 3755 Glossary Of Terms And Symbols (Part 2) Page 1085 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4988 SST. b. Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. 1. Remove the steering column lower cover. Remove the 3 screws and steering column lower cover as shown in the illustration. 2. Disconnect the airbag connector of the spiral cable. 3. Connect the SST connector to the airbag connector of the spiral cable. SST 09082-00700 4. Move the SST at least 10 m (33 ft) away from the front of the vehicle. 5. Close all the doors and windows of the vehicle. NOTE: Take care not to damage the SST wire harness. 6. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal. Page 2954 Fuel Pressure: Testing and Inspection CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the front fuel pipe from the LH delivery pipe. d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and SST (adapter). SST 09268-45014 (09268-1190, 90405-06167) Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) e. Wipe off any splattered gasoline. f. Reconnect the negative (-) terminal cable to the battery. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a) to (e)) h. Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. i. Disconnect the TOYOTA hand-held tester from the DLC3. j. Start the engine. k. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) l. Stop the engine. m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45014 o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable to the battery. q. Check for fuel leaks. Page 6320 Cigarette Lighter: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4572 Starter (Part 2) Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 140 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Page 1995 Page 2703 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Page 5698 Page 600 A/F and 02 Sensor Identification Locations Page 572 Page 482 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications New gasket and the ECT sensor. Torque: .......................................................................................... .................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf) New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ............................................... .................................................................................................................................. 18 N.m (185 kgf.cm, 13 ft.lbf) Page 3082 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 2215 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1228 Exhaust: N = T + (A - 0.30 mm (0.012 inch)) 3. Select a new shim with thickness as close as possible to the calculated value. HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787 inch) to 2.80 mm (0.1102 inch). e. Place a new adjusting shim on the valve. f. Place the valve lifter. Page 6615 d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the buzzer stops sounding. If operation is not as specified, replace the combination meter. 4. INSPECT COMBINATION METER CIRCUIT Page 1753 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 4966 15. INSTALL RACK GUIDE SPRING CAP LOCK NUT a. Apply sealant to 2 or 3 threads of the lock nut. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Temporarily install the lock nut. c. Using a hexagon wrench to hold the rack guide spring cap, and using SST, torque the lock nut. SST 09922-10010 Torque: 51 Nm (520 kgf-cm, 38 ft. lbs.) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). d. Recheck the total preload. Preload (turning): 1.0 - 1.45 Nm (10 - 14.5 kgf-cm, 8.7 - 12.6 inch lbs.) e. Remove the Right-Hand and Left-Hand rack ends. 16. INSTALL RIGHT-HAND AND LEFT-HAND CLAW WASHERS AND RACK ENDS a. Install a new claw washer, and temporarily install the rack end. HINT: Align the claws of the claw washer with the steering rack grooves. b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end. SST 09922-10010 Torque: 76 Nm (770 kgf-cm, 56 ft. lbs.) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). Page 4283 (b) In this position. check the rear brake pressure If the measured value is not within the standard, replace the valve body. Page 4730 Engine Room R/B Details Page 97 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3895 Transmission Mode Indicator - A/T: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 5875 Wheel Opening Moulding Page 3842 a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4 switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and the 4HI indicator lights come on when the touch select high-low switch is in OFF position. HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position. - If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash. 3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals. Touch select 2-4 switch Touch select high-low switch: If continuity is not as specified, replace the center integration panel assembly. 4. INSPECT ACTUATOR RESISTANCE a. Using an ohmmeter, measure the resistance between terminals 1 and 2. Standard resistance: 0.3 - 100 Ohms b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground. Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the actuator assembly. Page 4959 NOTICE: Make sure to install the oil seal facing in the correct direction. d. Coat a new bearing with molybdenum disulfide lithium base grease. e. Using SST, press in the bearing. SST 09950-60010 (09951-00340), 09950-70010 (09951-07150) 2. IF NECESSARY, REPLACE 2 BEARINGS a. Using SST, press out the bearing. SST 09950-60010 (09951-00260), 09950-70010 (09951-07150) b. Using SST, press out the bearing from the rack housing. SST 09950-60010 (09951-00260), 09950-70010 (09951-07200) c. Coat a new bearing with molybdenum disulfide lithium base grease. d. Using SST, press in the bearing. SST 09950-60010 (09951-00310), 09950-70010 (09951-07150) e. Coat a new bearing with molybdenum disulfide lithium base grease. Page 6426 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 5969 Page 5582 Seat Belt Reminder Buzzer: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Restraints - OCS System Initialization Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 1920 CHART 12 CHART 13 Page 1038 Refrigerant: Fluid Type Specifications Type R-134a Page 2879 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 4123 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 5959 FOR SPECIAL SERVICE CAMPAIGN REAR FRAME CROSS MEMBER & LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION 2000-2003 MODEL YEAR TUNDRA Page 6672 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 5190 Wheel Fastener: Service and Repair Rear REPLACEMENT 1. REMOVE REAR WHEEL 2. REMOVE BRAKE DRUM AND GASKET 3. REMOVE REAR HUB BOLT Using Special Service Tool (SST) and a brass bar or an equivalent, remove the hub bolt. SST 09650-17011 4. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a brass bar or an equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer. 5. INSTALL NEW GASKET AND BRAKE DRUM 6. INSTALL REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 6313 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4815 Driver Side J/B And Integration Relay Page 4934 Key Reminder Switch: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Page 725 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Page 1546 4. Cycle the temperature control knob several times and confirm proper water control valve adjustment. Page 872 5. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3. Page 6829 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 3086 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 4165 Parts Information Page 4200 4. With ABS: Disconnect ABS speed sensor and wire harness clamp from steering knuckle. Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. Disconnect brake line. Using the following SST, disconnect the brake line. Use a container to catch the brake fluid. SST P/N: 09023-00100 6. Remove brake caliper and disc. A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper, and disc. 7. Remove shock absorber. Page 2269 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 275 Airbag Sensor Assembly: Service and Repair Removal and Installation Airbag Sensor Assembly REMOVAL NOTE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary (If the IC terminals are touched, the IC may be destroyed by static electricity.). 1. REMOVE LOWER CENTER COVER Remove the 2 clips and lower center cover. Page 5962 - Length: 6 in. ^ Ratcheting tie down strap (quantity 1) - Minimum Width & Length: 1 in. x 6 ft. ^ Bicycle Cable Lock (quantity 1) - Minimum Width & Length: 3/8 in. x 5 ft. - Built-in lock with key - Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent IV. Background On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame cross-member. In the worst case the spare tire stowed under the truck bed may become separated from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or associated brake lines. Testing and Inspection Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the switch. Page 2492 CHART 21 Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 2. BLEED MASTER CYLINDER HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. SST 09023-00100 (b) Slowly depress the brake pedal and hold it. (c) Block off the outlet plug with your finger, and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. Page 4271 Brake Shoe: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 1858 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Page 391 Key Reminder Switch: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2989 5. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3. Electrical Specifications Fuel Injector: Electrical Specifications Resistance Between Terminals 13.4 to 14.2 ohms at 68 deg F Page 4648 Engine Room R/B Details Page 3715 6. INSTALL SNAP RINGS a. Install 2 new snap rings of equal thickness which will allow 0 - 0.05 mm (0 - 0.0020 inch) axial play. HINT: Do not reuse the snap rings. 4WD rear Propeller shaft Page 4786 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5941 Page 4576 e. Connect the engine wire with the bolt. f. Install the starter with the 2 bolts. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 2. INSTALL INTAKE MANIFOLD ASSEMBLY 3. CONNECT THROTTLE BODY ASSEMBLY TO INTAKE MANIFOLD 4. INSTALL INTAKE AIR CONNECTOR 5. CONNECT ACCELERATOR CABLE 6. INSTALL THROTTLE BODY COVER Page 3873 c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 4LO position. d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO -> 4HI position. HINT: When inspecting the operation described, use a heater main relay. NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing. Locations EFI Main Relay: Locations Engine Room R/B Page 5032 Control Arm: Service and Repair Upper REMOVAL 1. REMOVE SHOCK ABSORBER WITH COIL SPRING 2. w/ ABS: DISCONNECT ABS SPEED SENSOR WIRE HARNESS CLAMPS Remove the 2 bolts and ABS speed sensor wire harness clamps from the steering knuckle and upper suspension arm. Page 96 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 4828 Alignment: Specifications Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Gauge: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 5885 2. COAT CONTACT SURFACE OF BODY WITH PRIMER "M" Using a brush, coat the body surface except the front and rear end with Primer M as shown in the illustration. Front end: 23 mm (0.91 in.) + 8 mm (0.31 in.) or less Rear end: 70 mm (2.76 in.) + 12 mm (0.47 in.) or less NOTE: Let the primer coating dry for 3 minutes or more. - Do not coat to the adhesive. - Do not keep any of the opened Primer M for later use. 3. INSTALL NEW MOULDING a. Using a heat light, heat the body and moulding. Body: 40 - 60 °C (104 - 140 °F) Moulding: 20 - 30 °C (68 - 86 °F) NOTE: Do not heat the moulding excessively. b. Lift the moulding release sheet from face of the moulding. NOTE: When the moulding release sheet is removed, make sure that no dirt or dust con get onto the uncoated area. c. Install the moulding. Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 3043 Fuel Return Line: Testing and Inspection INSPECTION INSPECT FUEL TANK AND LINE a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Page 565 Page 4880 a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the front housing. b. Coat a new oil seal lip with power steering fluid. c. Using Special Service Tool (SST), press in the oil seal. SST 09950-60010 (09951-00330), 09950-70010 (09951-07100) NOTICE: Make sure to install the oil seal facing in the correct direction. REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID 2. INSTALL VANE PUMP SHAFT WITH VANE PUMP PULLEY 3. INSTALL STRAIGHT PINS Using a plastic hammer, tap in 2 new pins to the front housing. NOTICE: Be careful not to damage the pins. 4. INSTALL CAM RING Install the cam ring with the inscribed mark facing outward. HINT: Align the holes of the cam ring with the straight pins. 5. INSTALL VANE PUMP ROTOR a. Install the vane pump rotor with the inscribed mark facing outward. b. Install a new snap ring to the vane pump shaft. Capacity Specifications Refrigerant: Capacity Specifications Charge Volume 600 +/- 50 g Page 5109 Page 5866 Wheel Opening Moulding Page 4030 Brake Pedal Assy: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK PEDAL HEIGHT Pedal height from dash panel: 164 - 174 mm (6.46 - 6.85 inch) 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Remove the scuff plate LH, cowl side trim LH, lower finish panel and No. 2 heater to register duct. (b) Disconnect the connector from the stop light switch. (c) Loosen the stop light switch lock nut and remove the stop light switch. (d) Loosen the push rod lock nut. (e) Adjust the pedal height by turning the pedal push rod. (f) Tighten the push rod lock nut. Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.) (g) Install the stop light switch and turn it until it lightly contacts the pedal stopper. (h) Connect the connector to the stop light switch. (i) Push in the brake pedal 5 - 15 mm (0.20 - 0.59 inch), turn the stop light switch to lock the nut in the position where the stop light goes off. (j) After installation, push in the brake pedal 5 - 15 mm (0.20 - 0.59 inch), check that stop light lights up. (k) After adjusting the pedal height, check the pedal free play. (l) Install the No. 2 heater to register duct, lower finish panel, cowl side trim LH and scuff plate LH. 3. CHECK PEDAL FREE PLAY (a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. (b) Push in the pedal by hand until the second point of resistance begins to be felt, then measure the distance as shown in the illustration. Pedal free play: 1 - 6 mm (0.04 - 0.24 inch) If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system. Stop light switch clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch) HINT: The free play to the first point of resistance is due to the play between the clevis and pin. It is 1 - 3 mm (0.04 - 0.12 inch) at the pedal. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 3533 f. After installation, confirm the following items. 1 When the shift lever is at P position and the pedal button is pushed by 7 mm (0.28 inch), shift lever should be locked by lock pin. 2 When the pedal button is released, the shift lever should be able to be shifted from P position to other positions. 3 When the shift lever is at N or D position and the pedal button is pushed by 7 mm (0.28 inch), the shift lever should be able to be shifted. g. Install the cable No. 2 to column upper bracket with the clip. h. Install the cable end to the sliding block of the column upper bracket with the screw. Torque: 2.2 Nm (23 kgf-cm, 19 inch lbs.) i. After installation, check the following items. 1 When the pedal button is pushed, shift lever should be locked. 2 When the pedal button is released, shift lever should be unlocked. 4. INSTALL STEERING COLUMN ASSEMBLY 5. ADJUST CABLE HOUSING a. Shift the shift lever to the P position. b. Turn the ignition key to LOCK. c. Loosen the 2 bolts and adjust the cable housing. HINT: Pedal button should touch the pedal plate cushion. - Brake pedal should not be moved by the pedal button. - Cable housing should not be toughed the brake pedal and the brake pedal plate cushion. d. Torque the 2 bolts. Torque: 10.5 Nm (110 kgf-cm, 8 ft. lbs.) 6. CONFIRM SHIFT LOCK SYSTEM OPERATION a. Only when the brake pedal is engaged and the ignition key is not at LOCK, should the shift lever be able to be shifted from P position to other positions. When the shift lever is at P position and the brake pedal is released, the shift lever should not be able to be shifted from P position to other positions. b. When the shift lever is not at P position, the ignition key should not be able to be turned to LOCK. Once when the shift lever is at P position, should the ignition key be able to be removed. c. Cable No. 1 and No. 2 should not be deformed by other parts located around the steering column. Page 4998 e. Draw a new line on the masking tape of the steering wheel as shown in the illustration. f. Measure the distance between the 2 lines on the masking tape of the steering wheel. g. Convert the measured distance to steering angle. Measured distance 1 mm (0.04 inch) = Steering angle approximately 1°. HINT: Make a note of the steering angle. 2. ADJUST STEERING ANGLE a. Draw a line on the RH and LH tie rod and rack ends where it can easily be seen. b. Using a paper gauge, measure the distance from RH and LH tie rod ends to the rack end screws. HINT: ^ Measure the RH side and LH side. ^ Make a note of the measured values. c. Remove the RH and LH boot clips from the rack boots. d. Loosen the RH and LH lock nuts. e. Turn the RH and LH rack end by the same amount (but in different directions) according to the steering angle. 1 turn 360° of rack end (1.5 mm ( 1.5mm ( 0.059 in.) horizontal movement ) = 12° of steering angle f. Tighten the RH and LH lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) NOTICE: Make sure that the difference in length between RH and LH tie rod ends and rack end screws are within 1.5 mm (0.059 inch). g. Install the RH and LH boot clips. Page 4396 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS Using a screwdriver, remove the 4 cylinder boot set rings and boots. 2. REMOVE PISTONS FROM CYLINDER (a) Prepare the wooden plate to hold the pistons. Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 5307 Receiver Dryer: Service and Repair REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of the installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. DISCONNECT 2 LIQUID TUBES FROM RECEIVER Remove the 2 bolts and disconnect the both tubes. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of the installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tubes. 3. REMOVE RECEIVER a. Remove the holder bolt and pull receiver downward. HINT: At the time of the installation, please refer to the following item. If receiver is replaced, add compressor oil to compressor. Add 20 cc (0.71 fl.oz.) Compressor oil: ND-OIL 8 or equivalent b. Remove the bolt and holder. INSTALLATION Installation is in the reverse order of removal. Page 5936 A. AFFECTED VIN RANGE III. Preparation A. PARTS ^ No parts are required for the inspection. B. EQUIPMENT & MATERIALS ^ Protective eyewear ^ Standard heater core hose Page 6542 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 814 6. INSPECT LIMIT SWITCH CONTINUITY a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the transfer shift lever and after checking the operating sound, disconnect the connector and inspect the continuity between each terminal. HINT: When shifting the actuator fork shaft, connect the connectors. 7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check the combination meter. 9. INSPECT 4WD CONTROL ECU Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side connector from the back side. Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transmission Capacity (Drain & Refill) ........................................................................................................................... up to 2.0L (2.1 US qt.) Page 1688 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 2927 2. Apply battery positive voltage across the terminals. 3. Check that air flows from ports. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Page 2089 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Page 5060 Page 682 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given. a. Check the heated oxygen sensors operation. b. See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 4349 A. Disconnect shock absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the 8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint. SRS/Interior - Seat Cover Replacement Caution Side Air Bag: Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution BODY BO014-05 Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES Models: '98 - '06 All Models November 10, 2005 TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now obsolete and should be discarded. Introduction Beginning in 1998, Toyota introduced side airbags as optional equipment. Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or other seat cover materials on vehicles due to the following: ^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in part, during an accident. ^ Modifications that negatively affect side airbag performance can result in severe occupant injuries. ^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety system. ^ The design of the seat is complex, integrating safety and strength with comfort and luxury. *NOTE: Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used due to the effect on proper airbag performance. Toyota strongly discourages modifying original equipment seats that have optional side airbags. Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident. Applicable Vehicles ^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags. Warranty Information Page 1857 Crankshaft Position Sensor Page 2173 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Testing and Inspection Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Page 3914 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3917 Electronically Controlled Transmission And A/T Indicator (Part 3) Page 6697 Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 6993 a. Install the front pillar garnish. b. Employ the same manner described above to the other side. 22. INSTALL ASSIST GRIPS a. Driver's side: Using a torx socket wrench, install the assist grip with the 2 torx screws. Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool) b. Passenger's side: Using a torx socket wrench, install the 2 assist grips with the 4 torx screws. Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool) c. Install the caps. 23. INSTALL INNER REAR VIEW MIRROR Install the inner rear view mirror as shown in the illustration. Page 4745 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 153 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 5013 Ball Joint: Diagrams Page 4914 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 4051 11. 4WD: Remove oil seal (inside). A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration above). B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. Remove axle hub from steering knuckle. A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. SST P/N: 09710-28012-01 (09710-07031) SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. Remove bearing from steering knuckle. Page 973 Refrigerant Line (Part 2) Page 4758 Fuse Block: Connector Views Engine Room R/B Capacity Specifications Steering - Lubricant Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 5570 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1773 Engine Control Module: Specifications Terminals Of ECU - Connector Pinouts (Part 2) Page 6707 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 2062 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 6688 Transmission Mode Indicator - A/T: Testing and Inspection ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 4, 7, 8 - GROUND : Approx. 13 Ohms O4 O/D MAIN SW 3 - 1 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S4 STOP LIGHT SW 1 - 2 : Closed with brake pedal depressed E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position S2, SL - E1 : 0 - 1.5 volts with vehicle not move STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F) OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F) VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with ignition SW on and throttle valve fully open VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off SPD - E1 : Pulse generation with vehicle moving 2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position +B - E1 : 9 - 14 volts with ignition SW at ON or ST position BATT - E1 : Always 9 - 14 volts P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever in 2 position 3 - 8 : Closed with shift lever in L position Page 1441 10. CHECK CRANKSHAFT PULLEY POSITION Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No.1 timing belt cover. 11. INSTALL RH, LH CAMSHAFT TIMING PULLEYS a. Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the timing pulley. b. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 12. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY a. Remove any oil or water on the LH camshaft timing pulley, and keep it clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley. c. Turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and LH camshaft timing pulley. Page 6966 a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration. b. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTE: Let the primer coating dry for 3 minutes or more. - Do not keep any of the opened Primer G for later use. 5. Slide type: COAT CONTACT SURFACE OF GLASS WITH PRIMER "G" a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration. b. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTE: Let the primer coating dry for 3 minutes or more. - Do not keep any of the opened Primer G for later use. 6. Fixed type: APPLY ADHESIVE Ground Locations Transmission Mode Indicator - A/T: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 559 CHART 16 CHART 17 Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3616 HINT: During reassembly please refer to the spring specifications to help you to discriminate between the different springs. Spring Retainer and clip Specifications Water Pump: Specifications Water Pump W/ Bolts, Stud Bolts, and Nut Bolt 21 Nm Stud Bolt and Nut 18 Nm Page 3805 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 6843 Light Auto Turn Off Page 678 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3811 b. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the 3 clamps with the 3 bolts. 7. FILL ATF AND CHECK FLUID LEVEL Page 1774 Terminals Of ECU - Connector Pinouts (Part 1) Page 3316 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Locations Page 3649 10. INSTALL COMPANION FLANGE a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid gear oil. c. Using SST to hold the flange, torque the nut. SST 09330-00021 Torque: 147 Nm (1,500 kgf-cm, 109 ft. lbs.) 11. ADJUST DRIVE PINION PRELOAD 12. STAKE DRIVE PINION NUT 13. CONNECT REAR PROPELLER SHAFT 2WD: See Propeller Shaft; Service and Repair. 4WD: See Propeller Shaft; Service and Repair. 14. FILL DIFFERENTIAL WITH HYPOID GEAR OIL Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.) Oil type: Hypoid gear oil API GL-5 Recommended oil viscosity: Above 18°C (0°F): SAE 90 Below -18°C (0°F): SAE 80W or 8OW-90 Capacity: 2WD: 3.15 liters (3.33 US qts., 2.77 Imp. qts.) 4WD: 2.95 liters (3.12 US qts., 2.60 Imp. qts.) Page 5773 Glossary Of Terms And Symbols (Part 1) Diagram Information and Instructions Lamp Control Module: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6759 INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 CONTINUITY If continuity is not as specified, replace the relay. Page 4076 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Page 3360 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 341 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 3448 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Locations Impact Sensor: Locations Front Airbag Sensor Page 4128 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Page 6371 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTE: Page 303 INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 311 b. Inspect the connector on the wire harness side. If circuit is not as specified, inspect the circuits connected to other parts. Page 528 Applicable Vehicles Page 2495 CHART 23 Page 1507 Part 2 of 3 Page 4520 Battery Charging Procedure If the battery requires charging, follow the procedures below using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8). 1. Connect the charger cables to the positive (+) and negative (-) battery terminals. 2. Plug the charger into the 110V outlet and turn the switch to the ON position. 3. Select appropriate USER ID (if applicable) and press the NEXT soft key. 4. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the GR8 Instruction Manual. 5. Press the NEXT soft key when the HELLO screen appears to proceed to the Main Menu. Page 3389 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Specifications Page 3006 j. Connect a TOYOTA hand-held tester to the DLC3. k. Connect the battery negative (-) cable to the battery. l. Turn the ignition switch ON, and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. m. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. n. Please refer to the TOYOTA hand-held tester operator's manual for further details. o. Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 56 - 69 cu.cm (3.4 - 4.2 cu in.) per 15 seconds Difference between each injector: 13 cu.cm (0.8 cu in.) or less If the injection volume is not as specified, replace the injector. 2. INSPECT LEAKAGE a. In the condition above, disconnect the tester probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 12 minutes b. Turn the ignition switch OFF. Page 3010 3. REMOVE FUEL PRESSURE PULSATION DAMPER Remove the pulsation damper, upper gasket, fuel main hose and lower gasket. CAUTION: Put a shop towel under the delivery pipe. - Slowly loosen the pulsation damper. 4. REMOVE ACCELERATOR CABLE BRACKET a. Disconnect the accelerator cable from the engine. b. Remove the 2 nuts and accelerator cable bracket. 5. DISCONNECT PCV HOSE FROM PCV VALVE 6. DISCONNECT VSV FOR EVAP a. Disconnect the VSV connector for EVAP. b. Disconnect the EVAP hose. c. Remove the accelerator cable clamp and VSV for EVAP from the intake manifold. 7. REMOVE THROTTLE BODY COVER BRACKET Remove the bolt and throttle body cover bracket. 8. DISCONNECT ENGINE WIRES a. Disconnect the engine wire clamps from the No.1 engine hanger and engine wire bracket. b. Disconnect the 2 wire clamps on the engine wire from the brackets on the RH delivery pipe. 9. REMOVE DELIVERY PIPES AND INJECTORS NOTE: Page 4539 Alternator: Testing and Inspection INSPECTION 1. INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.1 - 2.5 ohms at 20 °C (68 °F). If there is no continuity, replace the rotor. 2. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. 3. INSPECT SLIP RINGS a. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. b. Using vernier calipers, measure the slip ring diameters. If the diameter is less than minimum, replace the rotor. Page 631 Page 4174 21. 4WD: Using the following SSTs and a press, install the bearing spacer. SST P/N: 09950-60010 (09951-00650) SST P/N: 09950-70010 (09951-07150) 22. 4WD: Install new oil seal (inside). A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). SST P/N: 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. Install steering knuckle. A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. Connect the lower ball joint to the steering knuckle with 4 bolts. Page 1286 Drive Belt: Testing and Inspection INSPECTION INSPECT DRIVE BELT a. Visually check the belt for excessive wear, frayed cords, etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the ribs are found on the belt, it should be replaced. b. 5VZ-FE engine: Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension: New belt: 135 - 180 lbs. Used belt: 85 - 120 lbs. If the belt tension is not as specified, adjust it. HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing a 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 pulley. - After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. Page 1971 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 3565 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 1285 Page 2612 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 2418 Page 4219 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 Page 4753 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 3141 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 6792 Headlamp Relay: Testing and Inspection POWER SOURCE HEATER RELAY 1 - 2 : Closed with ignition SW on and heater blower SW on HEAD RELAY 2 - 1 : Closed with light control SW at HEAD position or dimmer SW at FLASH position Closed with engine running and parking brake lever released (w/ daytime running light) I23 IGNITION SW 2 - 3 : Closed with ignition key at ACC or ON position 2 - 4 : Closed with ignition key at ON or ST position 7 - 6 : Closed with ignition key at ON or ST position DIMMER RELAY (w/ DAYTIME RUNNING LIGHT) 4 - 3 : Closed with HEAD relay on and dimmer SW at HIGH or FLASH position Fuel Pump Relay Fuel Pump Relay: Testing and Inspection Fuel Pump Relay INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP) 3. INSPECT FUEL PUMP RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 4. INSPECT FUEL PUMP RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. 5. REINSTALL FUEL PUMP RELAY 6. REINSTALL RELAY BOX COVER Page 3710 Drive/Propeller Shaft: Tools and Equipment Propeller Shaft - SST (Special Service Tools) Propeller Shaft - Equipment Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection INSPECT FOG LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4672 Relay Box: Connector Views Engine Room R/B Page 3581 Electronically Controlled Transmission And A/T Indicator (Part 3) Removal and Installation Load Compensator: Service and Repair Removal and Installation REMOVAL 1. DISCONNECT SHACKLE NO. 2 FROM BRACKET (a) Remove the nut and cushion retainer, and disconnect the shackle No. 2. (b) Remove the 2 bushings and collar. (c) Remove the 2 bolts and shackle bracket. 2. REMOVE LSP & BV ASSEMBLY (a) Using SST, disconnect the 3 brake lines from the valve body. SST 09751-36011 (b) Remove the 2 valve bracket mounting bolts and the LSP & BV assembly. INSTALLATION Ground Locations Transmission Mode Indicator - A/T: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 6009 Application Chart Engine Controls - Error When Reprogramming ECU Engine Control Module: All Technical Service Bulletins Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Page 4298 9. Remove steering knuckle. A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: Remove grease cap. A. Mount the axle hub in a soft jaw vise. NOTE: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). B. Using a screwdriver, remove the grease cap. NOTE: Be careful not to damage the grease cap. Page 591 Engine Bank Identification Page 2902 Glossary Of Terms And Symbols (Part 1) Testing and Inspection Cargo Lamp Switch: Testing and Inspection INSPECT CARGO LIGHT SWITCH CONTINUITY a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster integration. c. Check the continuity exists between terminal 12 and terminal 1, with the switch ON. d. Check that no continuity exists between terminal 12 and terminal 1, with the switch OFF. If continuity is not as specified, replace the switch. Testing and Inspection Power Mirror Switch: Testing and Inspection Left side INSPECT MIRROR SWITCH INSPECTION Right side INSPECT MIRROR SWITCH INSPECTION If continuity is not as specified, replace the switch. Page 571 CHART 26 Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Body Outside Moulding Lower Side Moulding / Trim: Service and Repair Body Outside Moulding Body Outside Moulding REMOVAL 1. HEAT MOULDING Using a heat light, heat the moulding to 20 - 30 °C (68 - 86 °F). NOTE: Do not heat the moulding excessively. 2. REMOVE MOULDING Page 2931 Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under these conditions: 1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor. Page 3595 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Page 6521 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 3992 Hydraulic Control Assembly - Antilock Brakes: Diagrams ABS ACTUATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Part 1 of 2 Page 1080 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 160 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 3661 6. FILL DIFFERENTIAL WITH HYPOID GEAR OIL 7. INSTALL ENGINE UNDER COVER 8. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Disassembly and Reassembly DISASSEMBLY Page 2778 CHART 29 Page 5048 Page 2274 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 5927 Page 3570 Glossary Of Terms And Symbols (Part 1) Page 6285 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 6540 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 6318 Glossary Of Terms And Symbols (Part 1) Specifications Three-Way Catalytic Converter (TWC) System Page 2638 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1299 12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding the bracket forward (refer to illustration). 13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following sequence: bolt 2, bolt 1, bolt 3. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) 14. Remove the accessory drive belt tensioner. 15. Install the NEW accessory drive belt tensioner. 16. Reassemble in the reverse order of disassembly. 17. Refill cooling system. Page 6723 Glossary Of Terms And Symbols (Part 1) Page 6715 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 1923 CHART 16 CHART 17 Front Wheel Bearing: Service and Repair Front Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. Page 4417 Installation is in the reverse order of removal. HINT: After installation, fill brake reservoir with brake fluid and bleed brake system. - Check for leaks. Page 4439 Brake Master Cylinder: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE RESERVOIR (a) Remove the set screw and pull out the reservoir. Torque: 1.8 Nm (18 kgf-cm, 16 inch lbs.) (b) Remove the cap and strainer from the reservoir. 2. REMOVE 2 GROMMETS 3. PLACE CYLINDER IN VISE Page 5771 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2009 Heated Oxygen Sensor Page 3184 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 139 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 3577 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 6888 Lamp Control Module: Description and Operation LIGHT AUTO TURN OFF SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 9 of the integration relay through ECU IG fuse. Voltage is applied at all times to TERMINAL 6 of the integration relay through the TAIL fuse, and through the HEAD relay coil side [w/o daytime running light] or through the daytime running light relay (Main) [w/ daytime running light]. 1. NORMAL LIGHTING OPERATION With the light control SW turned to TAIL position, a signal is input into the integration relay. Due to this signal, the current flowing to TERMINAL 6 of the relay flows to TERMINAL 14 of the light control SW to TERMINAL 16 to GROUND, and taillights to turn on. With the light control SW turned to HEAD position, a signal is input into the integration relay. Due to this signal, the current flowing to the relay flows to TERMINAL 13 of the light control SW to TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the lights on. The taillight circuit is same as above. 2. LIGHT AUTO TURN OFF OPERATION With light on and ignition SW turned off (Input signal goes to TERMINAL 9 of the relay), when the driver's door is opened (Input signal goes to TERMINAL 14 of the relay), the relay operates and the current is cutoff which flows from TERMINAL 6 of the relay to taillight circuit and headlight circuit. As a result, all lights are turned off automatically. Page 126 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Page 4205 SST P/N: 09527-17011 B. Coat MP grease to the oil seal lip. 18. Install new dust cover and axle hub to steering knuckle. A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. SST P/N: 09649-17010 19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is installed completely. 20. 2WD: Install new lock nut. A. Using the following SST, install and torque a NEW lock nut to the axle hub. SST P/N: 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. Page 2575 Specifications Page 233 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Gauge: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 4137 Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. ^ 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Testing and Inspection Power Door Lock Switch: Testing and Inspection Master switch INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 6520 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 952 Drive Belt: Tools and Equipment Toyota Serpentine Belt Wrench AST tool# TOY 1914 The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008. - Lightweight and Slim design - Equipped with 14mm and 19mm, 12 point securing attachments - Works on most Toyota applications (except Hybrids) Contact AST for pricing. Page 4494 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR 2. REMOVE SPEED SENSOR (a) Remove the 2 clamp bolts, clamp nut and 5 resin clips holding the sensor wire harness from the axle and the fuel tank. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) HINT: When installing the rear sensor wire harness, never use the removed resin clips, which are service parts. - When replacing clips, set up new resin clips at the same angle of the removed resin clips. (b) Remove the bolt and speed sensor from the axle carrier. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check speed sensor signal. Page 3221 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Service and Repair Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 6489 Audible Warning Device Control Module: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 3361 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Page 6878 Glossary Of Terms And Symbols (Part 2) Page 2603 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 5229 Condenser HVAC: Service and Repair REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. 2UZ-FE engine REMOVE A/T OIL COOLER 3. REMOVE HORN 4. REMOVE HOOD LOCK 5. REMOVE CENTER BRACE 6. REMOVE RECEIVER AND HOLDER Page 501 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3999 Installation is in the reverse order of removal. HINT: After installation, fill brake reservoir with brake fluid and bleed brake system. - Check for leaks. Page 2497 CHART 24 Page 3007 c. Disconnect the negative (-) terminal cable from the battery. d. Remove the SST and fuel tube connector. SST 09268-41047, 09842-30070 e. Disconnect the TOYOTA hand-held tester from the DLC3. f. Reconnect the fuel inlet pipe to the fuel tube. Page 3485 Step 3 Description and Operation Brake Fluid Solenoid Valve Relay: Description and Operation ABS Solenoid Relay This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. Page 1728 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 496 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Page 976 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Locations Engine Room R/B Fuel Pump Relay Fuel Pump Relay: Testing and Inspection Fuel Pump Relay INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP) 3. INSPECT FUEL PUMP RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 4. INSPECT FUEL PUMP RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. 5. REINSTALL FUEL PUMP RELAY 6. REINSTALL RELAY BOX COVER Page 3759 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2843 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the oxygen sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2 c. Reconnect the oxygen sensor connector. 2. INSPECT OPERATION OF HEATED OXYGEN SENSORS Page 4664 Glossary Of Terms And Symbols (Part 2) Page 3350 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Page 4718 Auxiliary Power Outlet: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Locations Engine Room R/B Page 4445 Wheel Cylinder: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 5591 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 1498 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER Remove the 9 bolts, seal washers and cylinder head cover. 7. REMOVE LH CYLINDER HEAD COVER a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal washers and cylinder head cover. 8. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360°) and align the mark. 9. INSPECT VALVE CLEARANCE Testing and Inspection Speedometer Head: Testing and Inspection INSPECT SPEEDOMETER ON-VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer. INSPECT SPEEDOMETER RESISTANCE Measure the resistance between terminals while fixing pointer to the stopper. If resistance value is not as the specified, replace the meter. Electrical Specifications Resistance Page 4537 Alternator: Diagrams Generator (Part 1) Page 6281 Audible Warning Device Control Module: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 4954 1. REMOVE 2 TURN PRESSURE TUBES a. Using Special Service Tool (SST), remove the 2 turn pressure tubes. SST 09023-12700 b. Remove the 4 O-rings from the tubes. 2. SECURE PS GEAR ASSEMBLY IN VISE Using SST, 2 bolts and nuts, secure the gear assembly in a vise, as shown in the illustration. SST 09612-00012 Reference: Bolt: 90105-10346 Nut: 90170-10198 HINT: Use 2 of the same type of SST 3. REMOVE RIGHT-HAND AND LEFT-HAND TIE ROD ENDS AND LOCK NUTS a. Place matchmarks on the tie rod end, lock nut and rack end. b. Loosen the lock nut, remove the tie rod end and lock nut. c. Employ the same manner described to the other side. Page 1925 CHART 20 Page 6849 Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 5803 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 4887 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 1115 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Locations Clockspring Assembly / Spiral Cable: Locations Steering Wheel Pad And Spiral Cable Front Wheel Fastener: Service and Repair Front REPLACEMENT 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake caliper and disc. c. Support the brake caliper securely. 3. REMOVE HUB BOLT Using Special Service Tool (SST) and a screwdriver or an equivalent, remove the hub bolt. SST 09650-17011 4. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a screwdriver or an equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer. 5. INSTALL BRAKE DISC AND CALIPER a. Install the brake disc, caliper and 2 bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) b. Install the brake line clamp to the steering knuckle with bolt. Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.) 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 7. DEPRESS BRAKE PEDAL SEVERAL TIMES Page 5835 promoters. However, the application of adhesion promoters on earlier model bumpers made from PP/TPU (Polypropylene/Thermoplastic Urethane) and PUR (Polyurethane) is also recommended. Page 5939 Page 6726 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 689 Voltage: 4.2 - 4.8 V d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor. Page 4181 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Page 4185 Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. ^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). Page 5099 Page 1509 Water Pump: Service and Repair Page 5400 3. Connect the SST connector to the airbag connector of the spiral cable. SST 09082-00700 4. Move the SST at least 10 m (33 ft) away from the front of the vehicle. 5. Close all the doors and windows of the vehicle. NOTE: Take care not to damage the SST wire harness. 6. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal c. Deploy the airbag. 1. Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. 2. Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. d. Dispose the steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. HINT: When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. Deployment When Disposing of Steering Wheel Pad DISPOSAL Page 2004 CHART 29 Page 1736 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 1909 Service and Repair Fluid Pump: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transfer Case; Service and Repair. Page 4428 6. BLEED BRAKE LINE 7. CHECK AND ADJUST LSP & BV FLUID PRESSURE Page 1979 CHART 5 CHART 6 Electrical Specifications Resistance Page 5054 A. AFFECTED VIN RANGE III. Preparation A. PARTS ^ No parts are required for the inspection. B. EQUIPMENT & MATERIALS ^ Protective eyewear ^ Standard heater core hose Page 17 Driver Side J/B And Integration Relay Page 4757 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5174 8. REMOVE STEERING KNUCKLE a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION 1. INSTALL STEERING KNUCKLE a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTICE: Be careful not to damage the oil seal and drive shaft boot. b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm (1,100 kgf-cm, 77 ft. lbs.) 2. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER a. Install the disc, brake caliper and 2 bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) b. Install the brake line clamp to the steering knuckle with bolt. Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.) 5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.) 6. 4WD: INSTALL DRIVE SHAFT LOCK NUT a. While applying the brakes, tighten the nut. Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.) b. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 9. DEPRESS BRAKE PEDAL SEVERAL TIMES 10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL Disassembly and Reassembly Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 4333 Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. ^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). Page 5377 Airbag Sensor Assembly: Service and Repair Removal and Installation Airbag Sensor Assembly REMOVAL NOTE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary (If the IC terminals are touched, the IC may be destroyed by static electricity.). 1. REMOVE LOWER CENTER COVER Remove the 2 clips and lower center cover. Page 4186 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. ^ 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. ^ 09710-28012-01 (09710-07031) ^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 1501 Exhaust: N = T + (A - 0.30 mm (0.012 inch)) 3. Select a new shim with thickness as close as possible to the calculated value. HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787 inch) to 2.80 mm (0.1102 inch). e. Place a new adjusting shim on the valve. f. Place the valve lifter. Page 6184 Cruise Control: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 3666 3. CHECK BEARING BACKLASH AND AXLE SHAFT DEVIATION a. Using a dial indicator, check the backlash in the bearing shaft direction. Maximum: 0.7 mm (0.028 inch) If the backlash exceeds the maximum, replace the bearing. b. Using a dial indicator, check the deviation at the surface of the axle shaft outside the hub bolt. Maximum: 0.1 mm (0.004 inch) If the deviation exceeds the maximum, replace the axle shaft. 4. w/ ABS: REMOVE ABS SPEED SENSOR FROM REAR AXLE HOUSING Remove the bolt and ABS speed sensor. 5. REMOVE REAR BRAKE ASSEMBLY 6. DISCONNECT BRAKE LINE AND PARKING BRAKE CABLE a. Using Special Service Tool (SST), disconnect the brake line from the wheel cylinder. SST 09023-00100 b. Remove the clip and pin, and disconnect the parking brake cable. 7. REMOVE REAR AXLE SHAFT ASSEMBLY a. Remove the 4 backing plate mounting nuts. b. Pull out the rear axle shaft assembly from the rear axle housing. NOTICE: Be careful not to damage the oil seal. 8. REMOVE O-RING FROM REAR AXLE HOUSING INSPECTION 1. w/ ABS: REMOVE BEARING RETAINER (DIFFERENTIAL SIDE) AND ABS SPEED SENSOR ROTOR a. Attach 4 nuts to the serration bolts and using a hammer remove the serration bolts from the backing plate. NOTICE: At the time of installation, do not reuse the nuts. Page 6199 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2438 Page 6291 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 2097 Step 1 Page 1983 CHART 11 Page 5607 Seat Belt Reminder Lamp: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6405 Key Reminder Switch: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 5097 Page 3940 Steps 1 - 2 Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2352 Terminals Of ECU - Connector Pinouts (Part 2) INSPECTION 1. REMOVE ECM 2. INSPECT ECM 3. REINSTALL ECM Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 2. BLEED MASTER CYLINDER HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. SST 09023-00100 (b) Slowly depress the brake pedal and hold it. (c) Block off the outlet plug with your finger, and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. Page 2936 Leak Detection Solenoid: Testing and Inspection VSV FOR VAPOR PRESSURE SENSOR INSPECTION 1. REMOVE VSV 2. INSPECT VSV a. Inspect the VSV for open circuit. Using an ohmmeter, check that there is no continuity between the terminals. Resistance: 37 - 44 ohms at 20 °C (68 °F) If there is no continuity, replace the VSV. b. Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. c. Inspect the VSV operation. 1. Check that air flows from ports E to G. Page 4983 2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. - If there is slackness in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free due to the shock from the airbag deploying. - Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel d. Check functioning of the SST. Page 6414 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Testing and Inspection Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Page 6052 be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken paint. Page 3575 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2270 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 5601 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5762 Trailer Connector: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) 2ND Gear Clutch Clutch: Specifications 2nd Coast Brake Piston Stroke 1.5 - 3.0 mm Piston Rod Length 72.9 mm 71.4 mm 2nd Brake Pack Clearance 0.50 - 1.76 mm Piston Return Spring Standard Free Length 16.61 mm Page 639 CHART 28 Page 5129 3. REMOVE U-BOLTS a. Remove the 4 U-bolt mounting nuts and washers. b. Remove the spring seat and 2 U-bolts. c. Remove the spring bumper. 4. REMOVE LEAF SPRING a. Remove the nut, washer and bolt. b. Remove the 2 nuts, washers, bolts, shackle and leaf spring. REPLACEMENT 1. REPLACE BUSHINGS a. Using a saw, cut the both bushing tabs as shown in the illustration. Upper Page 6341 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 1793 Engine Control Module: Connector Views Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Page 3111 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 2205 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 3631 4. INSPECT A.D.D. RELAY a. Check the continuity between each terminal, as shown in the chart. *: There is a diode between the terminals 6 and 7. If no continuity exists, check that continuity exists when changing the position of (+) probe for the position of negative (-) probe of tester. b. Apply battery positive voltage between each terminal and check the continuity between each terminal, as shown in the chart. If continuity is not as specified, replace the relay. 5. INSPECT TRANSFER 4WD POSITION SWITCH 6. REMOVE A.D.D. ACTUATOR 7. INSPECT CLUTCH HUB AND CLUTCH SLEEVE a. Check the clutch hub and clutch sleeve for wear and damage. If necessary, replace them. b. Check that clutch sleeve slides smoothly on the clutch hub. 8. MEASURE SLEEVE FORK AND CLUTCH SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve. Page 349 Engine Coolant Temperature (ECT) Sensor Page 674 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1768 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Drivetrain - Revised Rear Axle Oil Seal/Installation Seals and Gaskets: Technical Service Bulletins Drivetrain - Revised Rear Axle Oil Seal/Installation DRIVELINE & DIFFERENTIAL DL002-03 August 6, 2003 Title: REAR AXLE SEAL DESIGN CHANGE Models: '01 - '02 Sequoia, '95 - '02 Tacoma & '00 - '02 Tundra Introduction The rear axle seal lip design has been changed from a flat face type to an angled face type. A different SST seal driver is required to install the seal properly and prevent damaging the oil seal during the installation process. NOTE: Use of SST part number 09951-00610 (Replacer 6-4) as listed in the Repair Manual to install the newly designed rear axle seal can damage the seal assembly causing it to leak. Repair Manual update on Technical Information System (TIS) is in process. Applicable Vehicles ^ 2001 - 2002 model year Sequoia vehicles. ^ 1995 - 2002 model year Tacoma vehicles. ^ 2000 - 2002 model year Tundra vehicles. Parts Information Required SSTs NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Required Tools & Material Warranty Information Identification Procedure Page 5175 DISASSEMBLY 1. 2WD: REMOVE GREASE CAP a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 2. 4WD: REMOVE OIL SEAL (INSIDE) a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). Page 5794 Trailer Connector: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 1241 Valve Cover: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 1460 Fuel Pressure: Testing and Inspection CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the front fuel pipe from the LH delivery pipe. d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and SST (adapter). SST 09268-45014 (09268-1190, 90405-06167) Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) e. Wipe off any splattered gasoline. f. Reconnect the negative (-) terminal cable to the battery. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a) to (e)) h. Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. i. Disconnect the TOYOTA hand-held tester from the DLC3. j. Start the engine. k. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) l. Stop the engine. m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45014 o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable to the battery. q. Check for fuel leaks. Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transmission Capacity (Drain & Refill) ........................................................................................................................... up to 2.0L (2.1 US qt.) Service and Repair Fuel Pressure Release: Service and Repair SFI SYSTEM PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector. b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. Page 2047 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Page 1895 A/F and 02 Sensor Identification Page 3154 Knock Sensor: Locations Knock Sensor (Part 1) Locations Engine Room R/B Page 4129 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Repair Procedure Electrical Specifications Resistance Page 3126 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 5391 Clockspring Assembly / Spiral Cable: Description and Operation SPIRAL CABLE (in COMBINATION SWITCH) A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. Page 5486 A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration. HINT: Preventing the seat belt from retraction with a clip will make the following work easier. B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped side to the anchor. C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by moving the Velcro tape several times as shown in the illustration. NOTE: Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly. 2. INSTALL FLUOROCARBON RESIN TAPE A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration. NOTE: Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Front Seat Cover - Damaged Seat Bottom Frame: All Technical Service Bulletins Front Seat Cover - Damaged BODY BO006-02 Title: FRONT SEAT COVER DAMAGE Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats March 1, 2002 Introduction Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could potentially wear a hole into the seat cover material during entry and exit of the vehicle. This condition has been addressed and corrected in production. The instructions below will illustrate how to properly repair vehicles with this condition. Applicable Vehicles 2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN shown below. 2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN shown below. Production Change Information Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT BRAKE LINE Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) Page 2847 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 6841 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Specifications Brake Fluid: Specifications Required Brake Fluid FMVSS No. 116 DOT3 Page 336 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR 2. REMOVE SPEED SENSOR (a) Remove the 2 clamp bolts, clamp nut and 5 resin clips holding the sensor wire harness from the axle and the fuel tank. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) HINT: When installing the rear sensor wire harness, never use the removed resin clips, which are service parts. - When replacing clips, set up new resin clips at the same angle of the removed resin clips. (b) Remove the bolt and speed sensor from the axle carrier. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check speed sensor signal. Page 4082 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 Page 5494 Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with a clip or tape. 2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal pliers. NOTE Be careful not to damage the webbing, since this may compromise the safety of this seatbelt. CAUTION Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MUST be replaced if: ^ The webbing is cut, frayed, worn, or damaged. ^ It has been used during a severe impact (inspect the label to ensure no impact damage has occurred) Page 5225 AFTER REASSEMBLY, CHECK MAGNETIC CLUTCH CLEARANCE a. Set the dial indicator to the pressure plate of the magnetic clutch. b. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. c. Check the clearance between the pressure plate and rotor when connecting the negative (-) terminal to the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Standard thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) Page 2348 Terminals Of ECU - Connector Pinouts (Part 2) Page 2334 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Diagrams Page 1063 Engine Room R/B Details Page 2162 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 6732 Brake Lamp: Electrical Diagrams Service Hints S4 STOP LIGHT SW 2 - 1 : Closed with brake pedal depressed Page 2863 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 6210 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2149 g. Reinstall the camshafts. h. Reinstall the timing belt. i. Recheck the valve clearance. 11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP COVER Page 230 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 5291 Heater Core Case: Testing and Inspection HEATER UNIT INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. Page 49 Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 4637 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 4633 Glossary Of Terms And Symbols (Part 2) Page 998 Fluid - A/T: Testing and Inspection FLUID INSPECTION 1. Check fluid level, as follows: NOTE: Drive the vehicle so that the engine and transaxle are at normal operating temperature. ATF temperature: 70 - 80°C (158 - 176°F). Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. a. Park the vehicle on a level surface and set the parking brake. b. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from the Park (P) to Low (L) position and return to the P position. c. Pull out the oil level gauge and wipe it clean. d. Push it back fully into the pipe. e. Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add new Automatic Transmission Fluid. Fluid type: ATF D-II or DEXRON III (DEXRON II) NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. Page 3235 Glossary Of Terms And Symbols (Part 2) Page 4756 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4862 Power Steering Fluid: Testing and Inspection INSPECTION 1. CHECK FLUID LEVEL a. Keep the vehicle level. b. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON(R) II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir/reservoir cap dipstick. If the fluid is cold, check that it is within the COLD LEVEL range. c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. f. With the engine idling, measure the fluid level in the oil reservoir. g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 inch) If a problem is found, bleed power steering system. i. Check the fluid level. Electrical Specifications Page 2333 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 213 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 1786 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6319 Glossary Of Terms And Symbols (Part 2) Testing and Inspection Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure at Idle .............................................................................................................................. ........................................................................ 29 kPa Oil Pressure at 3000 rpm ............................... .................................................................................................................................................... 294-588 kPa Service and Repair Valve Guide: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 6541 Seat Belt Reminder Lamp: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 714 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Page 1473 e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time. 4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away. 5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag. g. Observe these precautions when connecting the fuel tube connector (quick type): 1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe. Page 5536 Rear Seat Belt Extender Applications NOTE: A seat belt extender must not be used for the center rear seat belt. Part Number Information Owner Instructions Page 6598 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 5347 b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Standard cab: Check for deformation of the quarter panel. - Access cab: Check for deformation of the ELR bracket. - Check for damage on the connector and wire harness. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking item functioning of SST. - If the front seat outer belt has been dropped. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. Page 6419 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 3423 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 788 Steps 1 - 2 Page 2290 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Cooling System - Radiator Cap Inspection Procedure Radiator Cap: Technical Service Bulletins Cooling System - Radiator Cap Inspection Procedure ENGINE EG014-05 Title: RADIATOR CAP INSPECTION Models: All Toyota Models March 28, 2005 Introduction The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all Toyota models. Applicable Vehicles ^ All Toyota and Scion models. Required Equipment Warranty Information Page 417 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2609 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 5594 Seat Belt Reminder Lamp: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2870 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1978 CHART 2 CHART 3 CHART 4 Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... .......................................................... 0.15 - 0.25 mm Exhaust ........................................................... ............................................................................................................................................... 0.25 0.35 mm Page 4617 Driver Side J/B And Integration Relay Fuse Applications (Part 1) Page 2619 Page 1420 Camshaft Gear/Sprocket: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 3993 Part 2 of 2 Locations Airbag Sensor Assembly: Locations Instrument Panel Page 6253 Audible Warning Device: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Page 4782 Relay Box: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3896 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 474 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. Page 3978 Step 4 INSPECTION PROCEDURE HINT: Troubleshoot in accordance with the chart for each trouble symptom. Page 1552 1. Turn the temperature control knob to the full cold position. 2. Inspect the clearance between the water control valve lever and the lever stop. If the lever does not contact the lever stop, proceed to step 3. 3. If the lever does not contact the lever stop: A. Disengage the cable retaining clip. B. Pull up on the cable sheath until the water control valve lever contacts the lever stop. C. Re-fasten the cable retaining clip. Page 5504 NOTE: Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure. NOTE: If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the seat belt after it is completely dried, to confirm proper operation. Page 6427 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 6607 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4370 INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. 09023-00100 Page 151 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 6614 Key Reminder Switch: Component Tests and General Diagnostics INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key unlock warning system: INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer sounds. Specifications Brake Pad: Specifications Brake Pad Standard Thickness 11.5 mm Minimum Thickness 1 mm Page 3576 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3384 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 5931 Page 5804 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3340 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 3646 9. INSTALL COMPANION FLANGE a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid gear oil. c. Using SST to hold the flange, torque the nut. SST 09330-00021 Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 10. ADJUST DRIVE PINION PRELOAD 11. STAKE DRIVE PINION NUT 12. INSTALL FRONT PROPELLER SHAFT 13. FILL DIFFERENTIAL WITH HYPOID GEAR OIL Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) Oil type: Hypoid gear oil API GL-5 Recommended oil viscosity: SAE 75W-90 Capacity: 1.15 liters (1.22 US qts., 1.01 Imp. qts.) 14. INSTALL ENGINE UNDER COVER Page 3894 Splice Location B11 Ground Locations Seat Belt Reminder Lamp: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Testing and Inspection Power Window Switch: Testing and Inspection Driver's Switch Passenger's Switch : Window Unlock Passenger's Switch : Window Lock INSPECT POWER WINDOW MASTER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4608 Auxiliary Power Outlet: Electrical Diagrams Service Hints CIGARETTE LIGHTER AND POWER OUTLET C7 CIGARETTE LIGHTER 2 - GROUND : Approx. 12 volts with ignition SW at ON or ACC position 1 - GROUND : Always continuity P6, P7 POWER OUTLET 2 - GROUND : Approx. 12 volts with the ignition SW at ON or ACC position 1 - GROUND : Always continuity Page 3562 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 3580 Electronically Controlled Transmission And A/T Indicator (Part 2) Page 5321 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. - At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install them to the switch. INSTALLATION Installation is in the reverse order of removal. Page 5519 Seat Belt: Testing and Inspection INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts,nuts or sill-bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. Except manual type: RUNNING TEST (IN SAFE AREA) a. Fasten the front seat belts. b. Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. HINT: Conduct this test in a safe area. It the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver's seat belt (ELR): STATIC TEST a. Make sure that the belt locks when pulled out quickly. b. Remove the locking retractor assembly. c. Tilt the retractor slowly. d. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt. If a problem is found, replace the assembly. 3. Except driver's seat belt (ALR/ELR): STATIC TEST a. Make sure that the belt locks when pulled out quickly. b. Remove the locking retractor assembly. c. Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again. d. Make sure that the belt cannot be extended further. If a problem is found, replace the assembly. Page 6853 Engine Room R/B Page 1584 ^ The points shown in the rib sides near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates. b. Check the lock plate height (H) after completing the caulking. Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 inch) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 5. INSTALL DRAIN PLUG a. Install a new O-ring to the drain plug. b. Apply soapy water to the O-ring. c. Install the drain plug. 6. CHECK FOR WATER LEAKS a. Using SST, plug the inlet and outlet pipes of the radiator. SST 09230-01010 b. Using a radiator cap tester, apply pressure to the radiator. Test pressure: 147 kPa (1.5 kgf/cm2, 21 psi) c. Check for water leaks. HINT: On radiators with resin tanks, there is a clearance between the core plate and tank 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 performing the water leak test, first swirl the radiator around in the water until all air bubbles disappear. 7. INSTALL RADIATOR SUPPORTS Page 5732 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Service and Repair Camshaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 4833 Page 4383 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. ^ 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. ^ 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Page 5806 Glossary Of Terms And Symbols (Part 2) Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch Page 5477 - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 3383 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection 5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire harness side connector. Locations Engine Room R/B Specifications Fuel Pressure Regulator Page 4747 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 4632 Glossary Of Terms And Symbols (Part 1) Page 4143 Parts Information NOTE: Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly. Page 232 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 511 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Locations Fuse: Locations Driver Side J/B And Integration Relay Page 3073 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Page 5108 Blower Motor Blower Motor: Testing and Inspection Blower Motor INSPECTION 1. REMOVE BLOWER MOTOR a. Disconnect the connector. b. Remove the 3 screws and motor. 2. INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, then check that the motor operations smoothly. If operation is not as specified, replace the blower motor. 3. INSTALL BLOWER MOTOR a. Install the motor with the 3 screws. b. Connect the connector. Page 6986 a. Remove the 4 screws and windshield outside moulding. b. Employ the same manner described above to the other side. 13. REMOVE WINDSHIELD OUTSIDE UPPER MOULDING a. Using a knife, cut off the moulding as shown in the illustration. NOTE: Do not damage the body with the knife. b. Remove the remaining moulding. 14. REMOVE WINDSHIELD GLASS a. Push piano wire through between the body and glass from the interior. b. Tie both wire ends to wooden blocks or similar objects. HINT: Apply protective tape to the outer surface to keep the surface from being scratched. NOTE: When separating the glass, take care not to damage the paint and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. Lower Ball Joint: Service and Repair Lower REMOVAL 1. REMOVE FRONT WHEEL 2. LOOSEN 4 LOWER BALL JOINT SET BOLTS HINT: Do not remove the bolts. 3. DISCONNECT TIE ROD END a. Remove the coffer pin and nut from the tie rod end. b. Using Special Service Tool (SST), disconnect the tie rod end from the lower ball joint. SST 09610-20012 Page 1779 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3341 Page 4875 Power Steering Pump: Service and Repair Disassembly and Reassembly Page 4671 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5130 b. Using Special Service Tool (SST) and a press, press out the both inner tubes and rubber parts of the bushings. SST 09950-60010 (09951-00350) 09950-70010 (09951-07150) c. Using a chisel and hammer, tap out the outer tubes. d. Using SST and a press, install 2 new bushings. SST 09710-28012 (09710-07062), 09710-30041 09710-03211) 2. REPLACE LEAF SPRING a. Bend to open the spring clips. Using a chisel and hammer, pry up the 2 spring clips. b. Remove the center bolt and nut. Hold the spring near the spring center bolt in a vise and remove the center bolt and nut. c. Replace the spring clip. 1. Drill off the head of the rivet and drive it out. 2. Install a new rivet into the holes of the spring leaf and clip. Then rivet with a press. d. Install spring center bolt and nut. 1. Align the leaf spring holes and secure the leaves with a vise. 2. Install the spring center bolt and nut. Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.) Diagram Information and Instructions Lamp Control Module: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 4808 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3368 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 2017 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Recall - Rear Cross-Member Corrosion Technical Service Bulletin # SC90M Date: 091116 Page 6809 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2271 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Body - Acid Rain Paint Damage Prevention/Repair Paint: Technical Service Bulletins Body - Acid Rain Paint Damage Prevention/Repair TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR SECTION: EXTERIOR BULLETIN # 165 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2008 Condition & Cause 'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric impurities, often referred to as industrial fallout. The mixing forms varying degrees of corrosive acidic compounds that can settle on exposed surfaces. Depending on geographic location, concentration level, and length of exposure; vehicle paint finish damage can occur. Horizontal surfaces such as roof, hood, and trunk panels are most vulnerable. Prevention of Finish Damage While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term durability, if not cared for properly they can sustain damage as a result of acid rain exposure. Exposure can occur at any time in the life-cycle of a vehicle, be it transport, storage, or consumer use. Dealers should refer to the Toyota Warranty Policy and Procedures Manual, Policy No.2.3 for information on Storage and Protection of New Vehicles. Detailed information is also provided on proper finish care in the Owner's Manual of all models. In brief, following washing and wax application recommendations should keep paint looking good. Inspection & Repair Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water spotting however, advanced stages of damage result in etching and depressions from the corrosive effect. Lightly rubbing a finger across a suspected acid rain stain may help to confirm etching. University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides detailed information on paint finish types, damage assessment methods, and repair techniques. And, Collision Repair & Refinish T101 and L101 'Paint Finish Repair' provide hands-on training. There is no substitute for a good training experience. Visit (www.crrtraining.com) for more information about hands-on training. Locations Instrument Panel Page 5727 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Replacement Requirements Airbag Sensor Assembly: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 6678 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 5007 Inspection Information On-Vehicle Inspection NOTE: ^ Be sure to check the table for the applicable inspection type based on the vehicle model. ^ Refer to the table for the standard free play values. 1. Inspect Lower Ball Joint Free Play Page 1049 HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2 seconds. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Loosen the lock nut. (b) Adjust the length of the shackle No. 2. Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch) Adjustment range: 112 - 128 mm (4.41 - 5.04 inch) HINT: One turn of the nut changes the fluid pressure as shown in the following specification. 7.4 kPa (0.76 kgf/cm, 11 psi) (c) Torque the lock nut. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body. Low pressure-Lower body High pressure-Raise body (e) Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be adjusted, inspect the valve body. 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with the load sensing spring or move it. Page 6964 c. Push piano wire through from the interior. d. Tie both wire ends to wooden blocks or similar objects. HINT: Apply protective tape to the outer surface to keep the surface from being scratched. NOTE: When separating the glass, take care not to damage the paint and exterior. e. Cut the adhesive by pulling the piano wire around it. HINT: Cut the adhesive areas as shown in the illustration, leaving the adhesive where the stud bolts are. f. Let the piano wire pass as shown in the illustration, cut off the adhered part to the stud bolts. g. Remove the glass. NOTE: Leave as much of the adhesive on the body as possible when cutting off the glass. INSTALLATION HINT: For step 8 to 10, refer to Headliner. 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY Page 2622 Engine Control Module: Specifications Terminals Of ECU - Connector Pinouts (Part 2) Page 6681 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4933 Key Reminder And Seat Belt Warning Page 2544 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 6840 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 6224 Problem Symptom Confirmation (Road Test) PROBLEM SYMPTOM CONFIRMATION (Road Test) Page 5913 Page 1847 Engine Coolant Temperature (ECT) Sensor Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals with the switch ON (switch pin released). b. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 5338 Note 3 - Inspect and if necessary replace the Steering Wheel: ^ If the steering wheel is diagnosed as needing replacement during inspection Note 4 - Replace the Passenger Airbag assembly: ^ If the passenger airbag has been deployed or dropped ^ If the airbag is diagnosed as needing replacement when troubleshooting or during inspection Note 5 - Visually inspect and if necessary replace the following items if deformed: ^ Instrument panel and instrument panel reinforcement ^ Glove compartment or glove compartment door Note 6 - Replace the Front Impact Sensors: ^ If either the driver or passenger airbag has deployed (replace both front impact sensors) ^ If a front airbag sensor is diagnosed as needing replacement when troubleshooting or during inspection Note 7 - Replace the Airbag Sensor Assembly: ^ If any airbag has been deployed in a collision or the airbag sensor assembly has been dropped or is diagnosed as needing replacement when troubleshooting Note 8 - Inspect and if necessary replace the Wire Harness or Connector: ^ If any part of the SRS wire harness or any connector is diagnosed as needing replacement when troubleshooting or during inspection Note 9 - Replace the: ^ Side Impact Airbag if it has been deployed dropped or is diagnosed as needing replacement when troubleshooting or during inspection ^ Seat cover if it has cuts and/or frayed seams or is diagnosed as needing replacement during inspection ^ Seat frame if it is bent or has become damaged Note 10 - Replace the Side Impact Sensors: ^ If the side airbag assembly has been deployed dropped or is diagnosed as needing replacement when troubleshooting or during inspection Note 10 - Replace the Side and Curtain Shield Impact Sensors: ^ If either the side or curtain shield airbag assembly have been deployed dropped or are diagnosed as needing replacement when troubleshooting or during inspection Note 11 - In the event of driver or passenger airbag deployment replace all seatbelt Pretensioners. Note 12 - Replace the: ^ Curtain Shield Airbag if it has been deployed dropped or is diagnosed as needing replacement when troubleshooting or during inspection ^ Visually inspect and if necessary replace the following items if deformed or cracked: - Headliner and/or interior trim panels - Body components where the Curtain Shield Airbag is mounted Page 5774 Glossary Of Terms And Symbols (Part 2) Locations Engine Room R/B Vehicle - Long Term Storage Guidelines Battery: Technical Service Bulletins Vehicle - Long Term Storage Guidelines T-SB-0079-09 Rev1 March 4, 2009 Long Term Vehicle Storage Guidelines Service Category General Section Maintenance Market USA Applicability December 23, 2009 Rev1: TSB REVISION NOTICE ^ Applicability has been updated to include 2010 Prius PHV model and 2011 vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Long-term or off-site storage requires special care to keep vehicles factory fresh and ready for delivery. The following guidelines should be performed to minimize vehicle component/part degradation due to extended vehicle storage conditions. Long-term storage can affect a vehicle's systems and components. Any problems that are found should be corrected immediately. Required Tools & Equipment Warranty Information Procedure Page 5563 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Locations VSV For Vapor Pressure Sensor Page 2158 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 4524 Battery Replacement If a vehicle battery needs to be replaced for a warrantable condition, complete a Warranty Battery Label and affix it to the failed battery for proper warranty parts and claim processing. Include the Vehicle Identification Number ("IN) and warranty code on the Warranty Battery Label. Battery Maintenance Recommended Battery Maintenance: In addition to this new pre-delivery battery test, a monthly battery inspection is still required for stored vehicles. If your dealership is located in an area subject to extreme temperatures (hot or cold), periodic maintenance may need to be performed more frequently. To reduce parasitic battery drain on vehicles in storage for one week or more, the negative (-) battery cable should always be disconnected to reduce battery discharge. When the negative (-) battery cable is reconnected, please check and reset electrical components, such as the clock, radio, etc., and re-initialize all applicable systems/functions. Refer to the appropriate model and year service bulletins for specific details. For example: ^ TSB No. PD008-05, "Power System Initialization During PDS" (2005 model year) ^ TSB No. PDO14-06, "Power System Initialization During PDS" (2006 model year) Page 5520 e. Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. f. Tilt the retractor slowly. g. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. 4. Manual type: TESTING a. Adjust the belt to the proper length. b. Apply a firm load to the belt. c. Make sure that the belt does not extend. Page 1893 Page 82 Engine Room R/B Details Page 2254 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 6251 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 6225 a. Inspect the SET switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Push the control switch downward for the SET/COAST. 4. After releasing the switch, check that the vehicle cruises at the desired speed. b. Inspect the ACC (acceleration) switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check that the vehicle speed increases while the control switch is turned to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. 4. Momentarily push the control switch upward in the RES/ACC direction and then immediately release it. Check that the vehicle speed increases by about 1.5 km/h (Tap-up function). c. Inspect the COAST switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check that the vehicle speed decreases while the control switch is turned to SET/COAST; and the vehicle cruises at the set speed when the switch is released. 4. Momentarily push the control switch downward for the SET/COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap-down function). d. Inspect the CANCEL switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset. - Depress the brake pedal. - Shift into except D position. - Push the main switch OFF. - Pull the cruise control switch for CANCEL. Page 5088 Page 2534 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Page 6544 Splice Location B11 Page 4269 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1695 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 4522 10. Select the appropriate model and press the NEXT soft key. 11. Select OEM battery type and press the NEXT soft key. 12. Choose the correct battery (model number and CCA) and press the NEXT soft key. The battery will be tested before charging will occur. The progress bar fills in across the screen while testing. Page 3532 2. REMOVE PARKING LOCK CABLE ASSEMBLY a. Remove the screw and cable No. 2. b. Using a torx socket wrench, remove the 2 screws and cable No. 1. c. Remove the spring. d. Remove the 2 bolts and parking lock cable housing. 3. REMOVE SHIFT LEVER a. Disconnect the connector. b. Using a torx socket wrench, remove the torx screw and shift lever. c. Remove the upper No. 2 steering column cover. 4. REMOVE SHIFT LEVER HOUSING Using a torx socket wrench, remove the 3 torx screws and shift lever housing. INSTALLATION 1. INSTALL SHIFT LEVER HOUSING Using a torx socket wrench, install the shift lever housing with the 3 new screws. Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.) 2. INSTALL SHIFT LEVER a. Install the upper No. 2 steering column cover. b. Using a torx socket wrench, install the shift lever with a new screw. Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.) c. Connect the connector. 3. INSTALL PARKING LOCK CABLE NO. 1 AND NO. 2 a. Apply MP grease on the lock pin and internal surface of shift lever housing. b. Install the spring and parking lock cable No. 1 into the shift lever housing. NOTICE: Be careful not to bend or twist the cable abnormally. c. Using a torx socket wrench, install 2 new screws. Torque: 2.9 Nm (29 kgf-cm, 25 inch lbs.) d. Wire the cable No. 1 and No. 2. e. Install the cable housing to steering column assembly with 2 new bolts temporarily. NOTICE: Be careful not to bend or twist the cable abnormally. Page 3365 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 2180 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications New gasket and the ECT sensor. Torque: .......................................................................................... .................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf) New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ............................................... .................................................................................................................................. 18 N.m (185 kgf.cm, 13 ft.lbf) Page 5749 Wire Harness Fuse Location Troubleshooting Procedure Page 5602 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2801 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With filter .............................................................................................................................................. .......................................................... 6.4 Qts.(6.1L) Without filter ....................................................... ............................................................................................................................................ 6.0 Qts.(5.7L) Page 6080 4RUNNER LTD (Cladding & Overfender) 4RUNNER LTD Full Specifications Extension Housing: Specifications Extension Housing x Transmission Case 36 Nm No.2 Vehicle Speed Sensor x Extension Housing 5.4 Nm Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 2958 2. Tighten the union bolt by hand. 3. Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. Page 5879 Deck Top Protector Page 6930 Turn Signal Flasher: Testing and Inspection INSPECT TURN SIGNAL FLASHER OPERATION Disconnect the connector from the turn signal flasher and inspect the connector on the wire harness side,as shown. Instruments - Coolant Temperature Gauge Inaccurate Temperature Gauge: Customer Interest Instruments - Coolant Temperature Gauge Inaccurate ELECTRICAL EL009-01 October 12, 2001 Title: TEMPERATURE GAUGE INACCURATE Models: '00 - '01 Tundra Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the engine coolant temperature gauge displays an abnormally high reading during normal engine operating temperatures. To address this condition, an updated Temperature Gauge has been made available. Applicable Vehicles ^ 2000 - 2001 model year Tundra trucks, built prior to the VIN shown. Production Change Information Parts Information Repair Procedure IMPORTANT: Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the temperature gauge. 1. Remove the four bolts securing the combination meter assembly. 2. Replace the Temperature Gauge. 3. Reassemble the combination meter. Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 756 a. Install the front airbag sensors with the 4 bolts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) HINT: Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. NOTE: Connection of the connector is done after the sensor has been installed. - Make sure the sensor is installed with the specified torque. - If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with a new one. - The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. b. Connect the front airbag sensor connectors. c. Install the air cleaner assembly. d. 2UZ-FE engine: Install the battery tray, battery and battery carrier. Page 5503 Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film about 5 mm for each side. (Not fully released.) B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Match the shoulder belt anchor to the center of the tape. C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. NOTE: ^ Be sure to affix the fluorocarbon tape securely along all edges. ^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape. E. Remove the clip. F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocarbon resin tape and confirm the smoothness of the belt movement. Page 5614 Seat Belt Reminder Lamp: Electrical Diagrams Key Reminder And Seat Belt Warning Service Hints KEY REMINDER AND SEAT BELT WARNING Page 1317 Engine Oil: Fluid Type Specifications Engine Oil Type GRADE ..................................................................................................................................... API SJ Energy-Conserving or ILSAC multigrade engine oil All temperatures ............................................ ............................................................................................................................................ 5W-30 (preferred) Above 0° F ......................................................................................................................... ....................................................................................... 10W-30 Page 914 1. 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 mount bolt of the camshaft timing pulley. If there is any defect, as shown in the illustration, check these points: a. Premature parting - Check for proper installation. - Check the timing cover gasket for 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 even 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 timing cover for damage and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. INSPECT IDLER PULLEYS a. Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. b. Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. INSPECT TIMING BELT TENSIONER a. Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. Page 2771 CHART 25 Page 703 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 555 CHART 11 SRS/Interior - Seat Cover Replacement Caution Seat Cover: All Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution BODY BO014-05 Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES Models: '98 - '06 All Models November 10, 2005 TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now obsolete and should be discarded. Introduction Beginning in 1998, Toyota introduced side airbags as optional equipment. Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or other seat cover materials on vehicles due to the following: ^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in part, during an accident. ^ Modifications that negatively affect side airbag performance can result in severe occupant injuries. ^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety system. ^ The design of the seat is complex, integrating safety and strength with comfort and luxury. *NOTE: Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used due to the effect on proper airbag performance. Toyota strongly discourages modifying original equipment seats that have optional side airbags. Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident. Applicable Vehicles ^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags. Warranty Information Page 5810 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 6399 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTE: Page 2649 Windows 2000 SP2 or later Windows XP Pro SP1 or later For more information about the J2534 devices listed above, contact the vendors. To report compatibility problems with listed hardware/software, please contact the device manufacturer. For more information about Toyota vehicle reprogramming CDs or to report problems running Toyota's Calibration Update Wizard software, please contact Toyota. OBTAINING A CALIBRATION CD The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the Calibration Update Wizard application software for a Windows PC, and instructions for use. Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N 00456-REPRG-001. IMPORTANT NOTICE It is possible to permanently damage a vehicle controller during the flash reprogramming process. It is especially important to understand that once started, the reprogramming process must not be interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go into standby, hibernation or similar power management modes. The information provided herein is intended expressly for use by qualified professional automobile technicians. To prevent damage to your customer's vehicle and ensure safe service practice, read these materials completely and thoroughly before servicing the vehicle and be sure to follow all instructions. Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Front .................................................................................................................................................... ......................................................................... 1.2 Qt Rear ................................................................ .............................................................................................................................................................. 3.7 Qt Electrical Specifications Resistance Page 6992 Install the cowl louver with the 8 screws and 6 clips. 15. INSTALL WIPER ARMS a. Operate the wipers once and turn the wiper switch OFF. b. Install the wiper arms and tighten the nuts by hand. c. Adjust the installation positions of the wiper arms to the positions shown in the illustration. A: Approx. 25.7 mm (1.012 in.) B: Approx. 39.7 mm (1.563 in.) HINT: When installing wiper arms, make sure that the tips of the blades are not beyond the ceramic edge as indicated by "C" part in the illustration. d. Torque the nuts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) e. Install the caps. 16. INSTALL FRONT PART OF ROOF HEADLINING 17. INSTALL SUN VISOR HOLDERS Install the 2 sun visor holders with the 2 screws. 18. INSTALL FRONT PERSONAL LIGHT a. Connect the connector, then install the front personal light. b. Install the 2 screws and the clip. HINT: When installing the front personal light, attach the clip to the housing and push it to the bracket. c. Install the left side lens. 19. INSTALL SUB-VISORS Install the 2 sub-visors with the 4 screws. 20. INSTALL SUN VISORS a. w/ Light: Connect the connector. b. Install the 2 sun visors with the 4 screws. 21. INSTALL FRONT PILLAR GARNISH Page 6591 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 3739 Transmission Mode Indicator - A/T: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 5100 Page 4068 B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 148 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 5095 Page 4995 - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc.to a steering wheel pad with the deployed airbag. CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses. - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc.to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Page 6349 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4355 Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. Install shock absorber with coil spring. A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts. A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper, and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. Install new brake line. Using the SST, connect NEW brake line. SST P/N: 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. With ABS: Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: Install drive shaft lock nut. A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: Install grease cap. 31. Install front wheel. NOTE: Do NOT use an air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) Page 4692 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Locations Anti-Lock Brake System Page 2255 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Drivetrain - Drive/Axle Shaft Replacement Precautions Drive/Propeller Shaft: Technical Service Bulletins Drivetrain - Drive/Axle Shaft Replacement Precautions TRANSMISSION & CLUTCH TC003-07 Title: DRIVESHAFT ASSEMBLY REPLACEMENT Models: '90 - '07 Toyota Introduction The purpose of this bulletin is to provide information regarding anti-corrosion grease that is present on replacement driveshaft assemblies. It is important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may have come into contact with oil or foreign matter. Applicable Vehicles ^ 1990 - 2007 model year Toyota vehicles. Required Tools & Material Repair Procedure Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti-corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle. NOTE: A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information. Warranty Information Page 4752 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3891 Transmission Mode Indicator - A/T: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 4550 1. PLACE RECTIFIER END FRAME ON PULLEY 2. INSTALL ROTOR TO DRIVE END FRAME 3. INSTALL RECTIFIER END FRAME a. Place the generator washer on the rotor. b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. c. Install the 3 nuts. Torque: 4.5 N.m (46 kgf.cm, 39 in.lbf) 4. INSTALL PULLEY Page 4538 Generator (Part 2) Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 5906 Page 4108 Parts Information NOTE: Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly. Instruments - Coolant Temperature Gauge Inaccurate Temperature Gauge: Customer Interest Instruments - Coolant Temperature Gauge Inaccurate ELECTRICAL EL009-01 October 12, 2001 Title: TEMPERATURE GAUGE INACCURATE Models: '00 - '01 Tundra Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the engine coolant temperature gauge displays an abnormally high reading during normal engine operating temperatures. To address this condition, an updated Temperature Gauge has been made available. Applicable Vehicles ^ 2000 - 2001 model year Tundra trucks, built prior to the VIN shown. Production Change Information Parts Information Repair Procedure IMPORTANT: Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the temperature gauge. 1. Remove the four bolts securing the combination meter assembly. 2. Replace the Temperature Gauge. 3. Reassemble the combination meter. Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3750 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 6685 Electronically Controlled Transmission And A/T Indicator (Part 2) Page 4170 9. Remove steering knuckle. A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: Remove grease cap. A. Mount the axle hub in a soft jaw vise. NOTE: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). B. Using a screwdriver, remove the grease cap. NOTE: Be careful not to damage the grease cap. Page 4006 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 3398 Case: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Automatic Transmission/Transaxle; Service and Repair. Page 920 Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 21. INSTALL RH NO.3 TIMING BELT COVER a. Fit the RH No.3 timing belt cover, matching it with the fan bracket. b. Install the RH No.3 timing belt cover with the 3 bolts and nut. Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.) 22. INSTALL LH NO.3 TIMING BELT COVER a. Install the oil cooler pipe with the bolt and nut. b. Run the camshaft position sensor wire through the LH No.3 timing belt cover hole. c. Fit the LH No.3 timing belt cover, matching it with the fan bracket. d. Install the LH No.3 timing belt cover with the 4 bolts and nut. Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.) e. Install the wire grommet to the LH No.3 timing belt cover. f. Install the camshaft position sensor connector to the connector bracket. g. Connect the camshaft position sensor connector. h. Install the sensor wire to the wire clamp on the LH No.3 timing belt cover. i. Install the engine wire to the 2 wire clamps on the LH No.3 timing belt cover. 23. INSTALL DRIVE BELT IDLER PULLEY Install the idler pulley and cover plate with the bolt. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 24. INSTALL PS PUMP Install the PS pump with the 3 bolts. Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.) 25. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT a. Temporarily install the fan pulley, the fan, fluid coupling assembly with the 4 nuts. b. Install the drive belt. c. Tighten the 4 nuts holding the fluid coupling to the fan bracket. Torque: 21 Nm (215 kgf-cm, 16 ft. lbs.) 26. INTAKE AIR CONNECTOR ASSEMBLY 27. INSTALL THROTTLE BODY COVER 28. INSTALL RADIATOR ASSEMBLY 29. FILL WITH ENGINE COOLANT 30. START ENGINE AND CHECK FOR LEAKS Page 3005 Fuel Injector: Testing and Inspection Component Inspection INSPECTION 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. a. Disconnect the fuel inlet hose (fuel tube connector) from the fuel filter. b. Connect SST (attachment and hose) to the fuel tube. SST 09268-41047 (09268-52011) c. Remove the pressure regulator from the delivery pipe. d. Install the O-ring to the fuel inlet of the pressure regulator. e. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268-41047 (09268-41091) Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) f. Connect the fuel return hose to the fuel outlet of the pressure regulator. g. Install the O-ring to the injector. h. Connect SST (adapter and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41047 (09268-41110, 09268-41300) i. Put the injector into the graduated cylinder. CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. Locations Engine Room R/B Page 4579 HINT: At the time of assembly, please refer to the following item. Use a new O-ring. c. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. NOTE: Check that the positive (+) lead wires are not grounded. 6. REMOVE ARMATURE FROM FIELD FRAME REASSEMBLY Reassembly is in the reverse order of disassembly. HINT: At the time of assembly, please refer to the following items. Use high-temperature grease to lubricate the bearing and gears when assembling the starter. REPLACEMENT 1. REPLACE REAR BEARING a. Using SST, remove the bearing. SST 09286-46011 b. Using a press, press in a new bearing. 2. REPLACE FRONT BEARING Description and Operation Brake Fluid Solenoid Valve Relay: Description and Operation ABS Solenoid Relay This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. Locations Intake Air Temperature Sensor: Locations Mass Air Flow (MAF) Meter The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 2776 Restraints - OCS System Initialization Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 3874 6. INSPECT LIMIT SWITCH CONTINUITY a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the transfer shift lever and after checking the operating sound, disconnect the connector and inspect the continuity between each terminal. HINT: When shifting the actuator fork shaft, connect the connectors. 7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check the combination meter. 9. INSPECT 4WD CONTROL ECU Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side connector from the back side. Page 4967 c. Using a brass bar and hammer, stake the washer. NOTICE: Avoid any impact on the rack. d. Employ the same manner described to the other side. 17. INSTALL RIGHT-HAND AND LEFT-HAND RACK BOOTS, CLAMPS AND CLIPS a. Ensure that the steering rack hole is not clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. b. Set a new clamp to the groove of the rack boot. c. Install the boot. NOTICE: Be careful not to damage or twist the boot. d. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010 e. Install the clip to the rack boot. f. Employ the same manner described to the other side. 18. INSTALL RIGHT-HAND AND LEFT-HAND TIE ROD ENDS AND LOCK NUTS a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. b. After adjusting toe-in, torque the nut. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) Page 4736 Interior Panel Fuse Details Brakes - Front Brakes Vibrate Upon Application Technical Service Bulletin # BR004R-02 Date: 050404 Brakes - Front Brakes Vibrate Upon Application BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '05 Tundra September 12, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The following sections have been updated, expanded, or added: Introduction, Warranty Information, Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB. ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque specification in step 24, was changed. ^ September 8, 2003: A torque specification in step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improvements have been made to various brake components to help improve this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown. Production Change Information Page 1079 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 5726 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 4047 B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. NOTE: Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of brake vibration on this vehicle. G. Determine if TSB BROO4-02 has already been performed. Repair Procedure No. 1 1. Remove the front wheel. 2. 2WD: Using a screwdriver and hammer remove the grease cap. 3. 4WD: Disconnect drive shaft. A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 4577 Starter Motor: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE 2 DUST PROTECTORS 2. REMOVE FIELD FRAME AND ARMATURE a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) b. Remove the 2 through bolts. Torque: 1.4 kW type : 5.9 N.m (60 kgf.cm, 52 in.lbf) 2.0 kW type : 9.3 N.m (95 kgf.cm, 82 in.lbf) c. Pull out the field frame together with the armature from the magnetic switch assembly. NOTE: At the time of notice, please refer to the following items. Align the protrusion of the field frame with the groove of the magnetic switch. d. Remove the O-ring from the field frame. HINT: At the time of assembly, please refer to the following items. Use a new O-ring. 3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Page 4874 a. Install the air cleaner assembly with air cleaner hose and the 3 bolts. b. Install the clamp. c. Connect the hoses. d. Connect the MAF meter connector. 7. BLEED POWER STEERING SYSTEM Page 2586 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Page 951 Drive Belt: Service and Repair REMOVAL REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the drive belt. INSTALLATION INSTALL DRIVE BELT Turn the drive belt tensioner counterclockwise then install the drive belt. Page 4247 NOTE: If replacing the rear axle shaft and if the vehicle is equipped with ABS, ensure proper installation of the ABS speed sensor rotor and the bearing retainer (differential side). Use SST P/N: 09521-25011-01 to press and install a new sensor rotor and new bearing retainer to the axle shaft (Refer to Figure 2). 4. Replace the rear brake shoes and brake drums. For additional information on rear brake shoes and brake drum replacement, refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Brakes: Rear Drum Brake: Removal/Installation. 5. Adjust the PKB to specifications. 6. Remount the tire and wheel assembly to the vehicle. Torque all wheel nuts to the vehicle according to the vehicle specifications found in TIS: 2000 - 2005 model year Tundra Repair Manual: Brakes: Rear Drum Brake: Removal/Installation. 7. Road test the vehicle to determine if all brake vibration has been eliminated. 8. If brake vibration remains, determine if the vibration is from the front or the rear (while brakes are still warm from confirmation driving). If it is front vibration, refer to TSB No. BR004-02, Front Brake Vibration," for parts and repair information relating to Tundra front brake vibration. Page 2565 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 1194 Connecting Rod: Specifications Torque Specifications INSTALL CONNECTING ROD CAP BOLTS HINT: The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). - If any one of the connecting rod cap bolts is broken or deformed, replace it. a. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. b. Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.) If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. c. Mark the front of the connecting cap bolt with paint. d. Retighten the cap bolts by 90° as shown. e. Check that the painted mark is now at a 90° angle to the front. f. Check that the crankshaft turns smoothly. Page 4947 Page 3146 Ignition Coil: Service and Repair Ignition Coil REMOVAL Page 4948 REMOVAL 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE STEERING WHEEL PAD 3. REMOVE STEERING WHEEL 4. DISCONNECT RIGHT-HAND AND LEFT-HAND TIE ROD ENDS 5. DISCONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY 6. DISCONNECT CLAMP PLATE Remove the bolt and disconnect the clamp plate. Page 2976 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 5538 Seat Belt Extension: Technical Service Bulletins Seat Belt Extender - Increases Belt Length BODY BO023-01 September 14, 2001 Title: SEAT BELT EXTENDER Models: '00 -'02 Model Year Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. ^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. ^ The extender is available only in black. ^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network or Dealer Daily. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label on the part and review the Owner Instruction Sheet" with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer's file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper fitting to individual customers. This bulletin contains the following information: Procedure and Sample Label Application Charts Part Number Information Owner Instructions Seat Belt Extender Worksheet Applicable Vehicles ^ 2000 through 2002 model year Toyota vehicles. Page 1912 O2S Application Table O2S Failure Threshold Charts Page 6428 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2323 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 4785 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 6459 Oil Pressure Gauge: Testing and Inspection INSPECT OIL PRESSURE GAUGE RESISTANCE Measure the resistance between terminals A and B. If resistance value is not as specified, replace the receiver gauge. Page 5051 Information PRELIMINARY INSPECTION INSTRUCTIONS Deck Top Protector Upper Side Moulding / Trim: Service and Repair Deck Top Protector DECK TOP PROTECTOR Deck Top Protector REMOVAL Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ............................................................................................................................................... ............................................................. 1.0L (1.1 Qt) Page 5341 - There should be no interference between the instrument panel and the front passenger airbag assembly. CAUTION: Be sure to follow the correct procedure, for removal and installation of the front passenger airbag assembly. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED a. Do a diagnostic system check. b. Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle. - Check the deformation or cracks on the instrument panel and instrument panel reinforcement. - Check the damage on the connector and wire harness. HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. REPLACEMENT REQUIREMENTS CAUTION: Be sure to follow the correct procedure, for replacement of the front passenger air bag assembly. STEERING WHEEL PAD AND SPIRAL CABLE VEHICLE NOT INVOLVED IN COLLISION a. Do a diagnostic system check. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes b. Do a visual check which includes the following item with the steering wheel pad (with airbag) installed in the vehicle. Page 2763 CHART 20 Page 6674 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 240 Engine Control Module: Service and Repair VEHICLE REPROGRAMMING Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM). Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign provides direction to do so. Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool - Vetronix Mastertech - J2534 Compatible Vehicle Interface (Toyota validated and approved) REPROGRAMMING WITH SCANTOOL Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool, or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the authentic Toyota factory scantool software which runs on either of the above mentioned scantools. Scantool software version requirements are specified in applicable Technical Service Bulletin (TSB)/Service Communication (SC) documents. The Toyota/Lexus factory scantool and/or authentic factory software program cards can be purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card - P/N 01002593-005 for the "stand alone" program card Program cards are provided with the latest production version software available at time of purchase. Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system - Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software - Toyota/Lexus factory scantool program card - PC Interface Cable (P/N 01001090) to transfer data from PC to scantool - Calibration CD (00456-REPRG-001) REPROGRAMMING WITH J2534 INTERFACE Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface - Toyota Calibration Update Wizard software (available on calibration CD) - Personal Computer running Microsoft Windows 2000/XP or later operating system - Calibration CD (00456-REPRG-001) Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on this list. Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that their hardware works safely and efficiently with their products. Every device listed on this page has been thoroughly tested and validated on Toyota, Scion and Lexus vehicles. It is important to understand that only the specific devices, firmware, DLLs and APIs listed here have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware, DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's control; in some cases, changes made to device hardware/software can negatively impact reprogramming performance. Toyota makes every effort to continue to work with J2534 interface manufacturers to ensure continued product compatibility as the respective products evolve. Requirement for device: Supplier Device Name Version (Firmware* / DLL* / API*) Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04) Actia PassThru+ XS (02.01 / 02.01 / 04.04) Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04) EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04) Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04) Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04) * Original validated firmware/DLL versions may be superceded by the device manufacturer. Contact the device manufacturer if you are unable to find the versions listed above. Support OS: OS Name and Version: Page 6303 Cigarette Lighter: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 806 b. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the 3 clamps with the 3 bolts. 7. FILL ATF AND CHECK FLUID LEVEL Page 5119 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 147 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 3093 Throttle Body: Locations Throttle Body (Part 1) Page 5825 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. Note: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative. Page 6649 Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. w/ Tachometer Page 2564 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 1910 Page 4802 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Testing and Inspection Seat Sensor/Switch: Testing and Inspection Passenger's seat only: INSPECT SEAT BELT WARNING OCCUPANT DETECTION SENSOR CONTINUITY Check that continuity exists between the terminals 1 and 2 when pressing the sensing part. If operation is not as specified, replace the sensor. Page 2308 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Brakes - Front Brake Caliper Identification Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification BRAKES BR001-03 REVISED January 8, 2003 Title: FRONT BRAKE COMPONENT IDENTIFICATION Models: '00 - '05 Tundra, '01 - '05 Sequoia TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now obsolete and should be discarded. TSB REVISION NOTICE: March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note" added. The previous TSB should be discarded. Introduction There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are intended to assist you in identifying and ordering the correct replacement pads and fitting kits. Applicable Vehicles: ^ 2000 - 2005 model year Tundra vehicles. ^ 2001 - 2005 model year Sequoia vehicles. Warranty Information Page 4640 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5890 INSTALLATION 1. Temporarily install the new parts and measure each part in accordance with the body dimension diagram. 2. Temporarily install the front fender and hood, and check the fit. Locations EFI Main Relay: Locations Engine Room R/B Brakes - Front Brakes Vibrating Technical Service Bulletin # BR004R-02 Date: 040305 Brakes - Front Brakes Vibrating BRAKES BR004-02 REVISED September 16, 2002 Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra TSB REVISION NOTICE: ^ March 5, 2004: A torque specification in, step 24, was changed. ^ September 8, 2003: A torque specification in, step 28, was changed. The previous TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles ^ 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1494 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Page 4567 12. INSPECT BRUSH HOLDER INSULATION Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. 13. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idle gear and the clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the drive plate ring gear for wear or damage 14. INSPECT CLUTCH PINION GEAR Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the clutch assembly. 15. INSPECT FRONT AND REAR BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 16. DO PULL-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. Page 3566 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Testing and Inspection Oil Filter: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection; Procedures. Locations Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection INSPECT FUEL LEVEL WARNING LIGHT a. Disconnect the connector from the sender gauge. b. Connect terminals 1 and 3 on the wire harness side connector. c. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Testing and Inspection Washer Fluid Level Indicator: Testing and Inspection INSPECT WASHER LEVEL WARNING LIGHT a. Disconnect the connectors from the level warning switch. b. Connect terminals on the wire harness side connector of the level warning switch connector. c. Turn the ignition switch ON, check that the warning light come on. If the warning light does not light up, test the bulb. Page 4100 SST P/N: 09527-17011 B. Coat MP grease to the oil seal lip. 18. Install new dust cover and axle hub to steering knuckle. A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. SST P/N: 09649-17010 19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is installed completely. 20. 2WD: Install new lock nut. A. Using the following SST, install and torque a NEW lock nut to the axle hub. SST P/N: 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. Page 4346 Required SSTs Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. Specifications Water Pump: Specifications Water Pump W/ Bolts, Stud Bolts, and Nut Bolt 21 Nm Stud Bolt and Nut 18 Nm Page 4377 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Repair Procedure Page 2414 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 2749 Page 4943 Part 2 of 3 Page 6713 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 187 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Page 5937 - Length: 6 in. ^ Ratcheting tie down strap (quantity 1) - Minimum Width & Length: 1 in. x 6 ft. ^ Bicycle Cable Lock (quantity 1) - Minimum Width & Length: 3/8 in. x 5 ft. - Built-in lock with key - Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent IV. Background On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame cross-member. In the worst case the spare tire stowed under the truck bed may become separated from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or associated brake lines. Page 1930 CHART 23 Page 5252 REMOVE CENTER CLUSTER INTEGRATION PANEL a. Remove the 3 heater control knobs. b. Remove the 5 screws. c. Remove integration control panel by pulling the portions indicated by arrows in the illustration. d. Disconnect the connector. INSTALLATION Installation is in the reverse order of removal. Disassembly and Reassembly AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration) DISASSEMBLY 1. REMOVE AIRBAG INDICATOR CIRCUIT Release the 2 claws and remove the indicator circuit, then disconnect the connector. 2. REMOVE BULBS Remove the 5 bulbs. Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 2938 VSV For Vapor Pressure Sensor Page 5079 A. AFFECTED VIN RANGE III. Preparation A. PARTS ^ No parts are required for the inspection. B. EQUIPMENT & MATERIALS ^ Protective eyewear ^ Standard heater core hose Page 672 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Replacement Requirements Airbag Sensor Assembly: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 4221 Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). ^ 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Page 2018 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 2361 Knock Sensor: Locations Knock Sensor (Part 1) Page 3458 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2690 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Locations Engine Room R/B Page 4642 Driver Side J/B And Integration Relay Page 730 Knock Sensor: Locations Knock Sensor (Part 1) Page 1098 Engine Room R/B Details Component Locations Ignition Switch And Key Unlock Warning Switch Page 1166 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Page 592 A/F and 02 Sensor Identification Page 2628 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2811 CHART 5 CHART 6 Engine Controls - Techstream(R) ECU Re-Flash Procedure PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 6880 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Specifications Axle Nut: Specifications Front Drive Shaft Lock Nut 235 Nm (173 ft.lb) Page 1916 CHART 7 Page 4968 19. INSTALL 2 TURN PRESSURE TUBES a. Coat 4 new O-rings with power steering fluid and install them to the turn pressure tubes. b. Using SST, install the 2 turn pressure tubes. SST 09023-12700 Torque: 12 Nm (117 kgf-cm, 9 ft. lbs.) HINT: ^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch). ^ This torque value is effective in case that SST is parallel to a torque wrench. Page 2424 CHART 8 CHART 9 Page 3463 Transmission Mode Indicator - A/T: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4840 Measuring Point Reference 5. INSPECT TOE-IN If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN AND WHEEL ANGLE a. Remove the 2 clips. b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount 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 end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Page 2094 Knock Sensor: Locations Knock Sensor (Part 1) Page 5497 D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female part and is firmly held to the belt webbing. Page 3170 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 6603 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 5177 1. INSTALL NEW BEARING a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a new snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat MP grease to the oil seal lip. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS) NOTICE: Do not scratch the serration of the speed sensor rotor. 5. 2WD: INSTALL NEW LOCK NUT a. Using SST install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) b. Using a chisel and hammer, stake the lock nut. Page 2557 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Page 4926 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 98 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Restraints - OCS System Initialization Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 6206 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * 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 systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 6327 Cigarette Lighter And Power Outlet Page 1432 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. REMOVE RADIATOR ASSEMBLY 4. REMOVE THROTTLE BODY COVER 5. REMOVE INTAKE AIR CONNECTOR ASSEMBLY Page 6321 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Recall - Rear Cross-Member Corrosion Technical Service Bulletin # SC90M Date: 091116 Page 5975 Page 177 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 1784 Glossary Of Terms And Symbols (Part 1) Page 6733 Stop Light Page 6583 Key Reminder Switch: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2478 CHART 1 Page 2602 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 6666 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Locations Engine Room R/B Page 6214 Cruise Control: Description and Operation SYSTEM OUTLINE The cruise control system is a constant vehicle speed controller which controls the opening angle of the engine throttle valve by the SW, and allows driving at a constant speed without depressing the accelerator pedal. SET CONTROL When the SET/COAST SW is operated while traveling with the main SW on, the speed when the SET/COAST SW is operated to off is memorized, and the vehicle speed is controlled at that speed. COAST CONTROL When the SET/COAST SW is operated to on, the cruise control opening angle requirement is turned to 0 to decrease the vehicle speed, and the speed when the SET/COAST SW is operated to off is memorized, and the vehicle speed is controlled at that speed. Furthermore, every time the SET/COAST SW is operated momentarily (Approx. 0.5 sec.) to on, the memorized vehicle speed is decreased by approx. 1.5 km/h (0.9 mph). ACCEL CONTROL When the RES/ACC SW is operated to on, the throttle motor rotates the throttle valve to open direction to increase the vehicle speed, and the speed when the RES/ACC SW is operated to off is memorized, and the vehicle speed is controlled at that speed. Furthermore, every time the RES/ACC SW is operated momentarily (Approx. 0.5 sec.) to on, the memorized vehicle speed is increased by approx. 1.5 km/h (0.9 mph). MANUAL CANCEL MECHANISM If any of the following signals are input during cruise control traveling, the current to the motor flows in the direction to close the throttle valve, and cancel the cruise control. 1. Stop lamp SW is on (Brake pedal is depressed) 2. The CANCEL SW of the control SW is on 3. CRUISE SW is off RESUME CONTROL After canceling the cruise control (Except when the main SW is off) if the vehicle speed is above the minimum speed limit (Approx. 40 km/h, 25mph), operating the RES/ACC SW to on from off will cause the system to accelerate and resume to the vehicle speed before manual cancellation. OVERDRIVE FUNCTION The overdrive may be cut on an uphill grade, while traveling with the cruise control. After the overdrive is cut, if the vehicle speed reaches the overdrive resume speed (Set speed minus 2 km/h (1.2 mph) ), and if the system determines that the uphill grade has finished, the overdrive will resume after the overdrive timer operation. AUTO CANCEL OPERATION If any of the following conditions are detected, the set speed is erased and the control is canceled. 1. Disconnection and/or short in the stop light SW 2. Malfunction in the vehicle speed signal 3. Malfunction in the electronic throttle parts 4. Malfunction in the stop light SW input circuit 5. Malfunction in the cancel circuit 6. The actual vehicle speed becomes slower than the minimum speed limit 7. The actual vehicle speed becomes -16 km/h (10 mph) slower than the set speed Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 658 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Page 235 Terminals Of ECU - Connector Pinouts (Part 2) Component Locations Page 6842 Lamp Control Module: Electrical Diagrams Service Hints LIGHT AUTO TURN OFF HEAD RELAY 2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position. Closed with the engine running and the parking brake lever released (w/ daytime running light) C15 LIGHT CONTROL SW [COMB. SW] 13 - 16 : Closed with light control SW at HEAD position 14 - 16 : Closed with light control SW at TAIL or HEAD position D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Continuity with the front LH door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with the ignition SW at ON position 14 - GROUND : Continuity with the front LH door open 3, 6 - GROUND : Always approx. 12 volts 8 - GROUND : Always continuity ILLUMINATION C15 LIGHT CONTROL SW [COMB. SW] 14 - 16 : Closed with light control SW at TAIL or HEAD position Page 6724 Glossary Of Terms And Symbols (Part 2) Page 2973 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Page 414 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 398 Key Reminder Switch: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 5140 Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, see DISPOSAL. DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. REASSEMBLY 1. INSTALL COIL SPRING TO SHOCK ABSORBER a. Using Special Service Tool (SST), compress the coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: ^ Do not compress the coil spring more than necessary. ^ Do not use an impact wrench. It will damage the SST. b. Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the spring seat of the shock absorber. Page 1735 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Page 100 Relay Box: Connector Views Engine Room R/B Page 4759 Driver Side J/B And Integration Relay Page 1529 Engine Coolant Temperature (ECT) Sensor Page 6100 a. Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (-) lead to the battery negative (-) terminal, then move the seat cushion to the lowest position. b. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. c. Disconnect the leads from the terminals. d. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the seat cushion begins to ascend. If operation is not as specified, replace the seat adjuster. INSPECT RECLINING MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the seat adjuster. INSPECT RECLINING MOTOR PTC THERMISTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the ammeter to terminal 1 and the negative (-) lead to the battery negative (-) terminal, then recline the seat back to the most forward position. Page 2212 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Brakes - Front Brakes Vibrating Technical Service Bulletin # BR004R-02 Date: 040305 Brakes - Front Brakes Vibrating BRAKES BR004-02 REVISED September 16, 2002 Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra TSB REVISION NOTICE: ^ March 5, 2004: A torque specification in, step 24, was changed. ^ September 8, 2003: A torque specification in, step 28, was changed. The previous TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles ^ 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1488 Spark Plug: Application and ID Recommended Spark Plugs DENSO K20R-U NGK BKR6EYA Page 4409 Anti-Lock Brake System Recall - Rear Cross-Member Corrosion Technical Service Bulletin # SC90M Date: 091116 Page 1740 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 5514 Seat Belt: Specifications Seat Belt Page 4606 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2764 Page 6727 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 6102 move the lumbar support to front end position. b. Continue to apply voltage, check that a circuit breaker operation noise can be heard within 4 to 60 seconds. c. Reverse the polarity, check that the lumbar support begins to move release side with in approximately 60 seconds. If operation is not as specified, replace the lumber support adjuster. Page 2154 Mass Air Flow (MAF) Meter Page 1287 Drive Belt: Service and Repair REMOVAL REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the drive belt. INSTALLATION INSTALL DRIVE BELT Turn the drive belt tensioner counterclockwise then install the drive belt. Page 1719 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 227 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4569 Disconnect the negative (-) lead from the starter body. Check that the pinion gear returns inward. 4. DO NO-LOAD PERFORMANCE TEST a. Connect the battery and ammeter to the starter as shown. b. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified current Page 1074 Engine Compartment Instrument Panel Locations Page 1639 Part 3 of 3 Page 1687 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Application and ID Valve Spring Shim: Application and ID ADJUSTING SHIM SELECTION CHART Intake Page 5237 Connector View Pinouts (Part 1) Page 1434 11. REMOVE NO.2 TIMING BELT COVER Remove the 2 bolts and No.2 timing belt cover. 12. w/ A/C: DISCONNECT A/C COMPRESSOR FROM ENGINE 13. REMOVE FAN BRACKET Remove the 2 bolts, 2 nuts and fan bracket. 14. IF RE-USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks on the timing belt by turning the crankshaft pulley as shown in the illustration. HINT: If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part. 15. LOOSEN CRANKSHAFT PULLEY BOLT Using SST, loosen the pulley bolt. SST 09213-70010 (90100-08076), 09330-00021 16. SET NO.1 CYLINDER TO TDC/COMPRESSION Page 6606 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 6706 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 6884 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 6814 Glossary Of Terms And Symbols (Part 1) Page 6532 Key Reminder And Seat Belt Warning Page 6855 INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 CONTINUITY If continuity is not as specified, replace the relay. Page 142 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL 1. REMOVE FRONT WHEEL Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT SPEED SENSOR CONNECTOR 3. REMOVE SPEED SENSOR (a) Remove the clips and 3 clamp bolts holding the sensor harness from the frame, upper arm and steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) (b) Remove the bolt and speed sensor from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check speed sensor signal. Diagrams Cooling Unit Page 1859 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Page 472 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 149 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 5337 *Some Toyota vehicles are equipped with a Passenger Airbag Manual On-Off Switch, and other Toyota models may have a retrofit passenger airbag switch installed at the dealership. To analyze the condition of the manual on-off switch technicians must follow specific inspection procedures which are outlined in this bulletin. However complete airbag manual on-off switch inspection and repair procedures can be found in vehicle-specific Toyota Repair Manuals. Note - for all Toyota vehicles Following all collisions when the SRS does NOT deploy inspect: ^ Steering wheel pad ^ Side airbags and seat frames ^ Front & side airbag sensors ^ Wiring harness and connectors ^ Front passenger airbag assembly ^ Malfunction indicator lamp for correct operation Component Replacement Notes Note 1 - Replace the Steering Wheel Pad: ^ If the airbag has been deployed or dropped ^ If the steering wheel pad is diagnosed as needing replacement when troubleshooting or during inspection Note 2 - Inspect and if necessary replace the Spiral Cable: ^ If the spiral cable is diagnosed as needing replacement when troubleshooting or during inspection Page 2767 Page 2039 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2868 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 5420 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 1804 Page 6609 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 206 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 5102 FOR SPECIAL SERVICE CAMPAIGN REAR FRAME CROSS MEMBER & LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION 2000-2003 MODEL YEAR TUNDRA Page 2817 CHART 14 Page 5004 Page 2086 Crankshaft Position Sensor Symptom Related Diagnostic Procedures Problem Symptoms Table - Stop Light System Brakes - Front Brake Caliper Identification Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification BRAKES BR001-03 REVISED January 8, 2003 Title: FRONT BRAKE COMPONENT IDENTIFICATION Models: '00 - '05 Tundra, '01 - '05 Sequoia TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now obsolete and should be discarded. TSB REVISION NOTICE: March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note" added. The previous TSB should be discarded. Introduction There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are intended to assist you in identifying and ordering the correct replacement pads and fitting kits. Applicable Vehicles: ^ 2000 - 2005 model year Tundra vehicles. ^ 2001 - 2005 model year Sequoia vehicles. Warranty Information Page 2174 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Page 4695 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Instruments - Coolant Temperature Gauge Inaccurate Temperature Gauge: Customer Interest Instruments - Coolant Temperature Gauge Inaccurate ELECTRICAL EL009-01 October 12, 2001 Title: TEMPERATURE GAUGE INACCURATE Models: '00 - '01 Tundra Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the engine coolant temperature gauge displays an abnormally high reading during normal engine operating temperatures. To address this condition, an updated Temperature Gauge has been made available. Applicable Vehicles ^ 2000 - 2001 model year Tundra trucks, built prior to the VIN shown. Production Change Information Parts Information Repair Procedure IMPORTANT: Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the temperature gauge. 1. Remove the four bolts securing the combination meter assembly. 2. Replace the Temperature Gauge. 3. Reassemble the combination meter. Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 5516 Seat Belt Page 6801 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 4368 B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 1692 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 2866 Glossary Of Terms And Symbols (Part 1) Page 4944 Part 3 of 3 Page 6601 Glossary Of Terms And Symbols (Part 1) Page 3556 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 6525 Seat Belt Reminder Buzzer: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 5994 Roof Headlining Page 2779 CHART 30 Page 5656 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 2932 Voltage: 4.2 - 4.8 V d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor. Page 6718 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 716 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Page 1650 Three-Way Catalytic Converter (TWC) System Page 5957 Page 392 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 2830 Page 4994 - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN COLLISION CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses. - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Steering Wheel Airbag Disposal HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air bag in accordance with the procedure described. 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 steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-ofdoors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. Procedures Seat Belt Tensioner: Procedures Replacement Requirements REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking item functioning of SST. - If the front seat outer belt has been dropped. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. Deployment and Disposal 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 procedure described below. If any abnormality occurs in the seat belt pretensioner operation, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A.,INC. When disposing of a front seat outer belt (with seat belt pretensioner) activated in a collision, follow the same procedure given in step 1-(e) in "DISPOSAL". CAUTION: - Never dispose of front seat outer belt which has an inactivated pretensioner. - The seat belt pretensioner produces a sizeable exploding sound when it activates, so perform the operation out-of-door and where it will not create a nuisance to nearby residents. - When activating the seat belt pretensioner, always use the specified SST. (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700,09082-00740 - When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt. - Use gloves and safety glasses when handling a front seat outer belt with activated pretensioner. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front seat outer belt with activated pretensioner. 1. SEAT BELT PRETENSIONER ACTIVATION WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to activate the seat belt pretensioner. Page 1288 Drive Belt: Tools and Equipment Toyota Serpentine Belt Wrench AST tool# TOY 1914 The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008. - Lightweight and Slim design - Equipped with 14mm and 19mm, 12 point securing attachments - Works on most Toyota applications (except Hybrids) Contact AST for pricing. Page 2496 Page 3689 1. INSTALL NEW BEARING a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a new snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat MP grease to the oil seal lip. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS) NOTICE: Do not scratch the serration of the speed sensor rotor. 5. 2WD: INSTALL NEW LOCK NUT a. Using SST install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) b. Using a chisel and hammer, stake the lock nut. Page 2643 Terminals Of ECU - Connector Pinouts (Part 2) Page 5593 Splice Location B11 Page 4102 Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. Install shock absorber with coil spring. A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts. A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper, and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. Install new brake line. Using the SST, connect NEW brake line. SST P/N: 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. With ABS: Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: Install drive shaft lock nut. A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: Install grease cap. 31. Install front wheel. NOTE: Do NOT use an air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) Diagrams Front Door Window Glass: Diagrams Front Door (Part 1) Page 6238 Steps 1 - 3 Removal and Installation Starter Motor: Service and Repair Removal and Installation Starter (Part 1) Page 6123 * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type: Power Adjuster) section of the applicable service manual. 2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the location shown below. 3. Reassemble the front seat with the new seat cushion cover. NOTE: Do not use air tools when installing the seat assembly back into the vehicle. Page 2907 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 820 INSPECT PASSENGER'S DOOR POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT POWER WINDOW MASTER SWITCH CIRCUIT Disconnect the connector from the master switch and inspect the connector on the wire harness side. * Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver or a passenger's door is opened after the ignition switch is turned ON to OFF (ACC). If the circuit is not as specified, inspect the circuits connected to other parts. Page 1741 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 5302 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 5800 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2692 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Front Fluid - Differential: Service and Repair Front FILL DIFFERENTIAL WITH HYPOID GEAR OIL Page 1954 Page 2637 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 715 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Page 3548 1. REMOVE PIPE Loosen the 2 clips and disconnect the 2 hoses. 2. REMOVE OIL COOLER a. Remove the 3 bolts and oil cooler. Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.) b. Remove the bolt, transmission oil cooler bracket and grommet. Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.) c. Remove the 2 grommets and condenser mounting insulators. 3. REMOVE OIL COOLER TUBE a. Loosen the 2 clips and disconnect the 2 hoses. b. Remove the bolt and oil cooler tube with the 2 hoses. Torque: 5.0 Nm (50 kgf-cm, 48 inch lbs.) c. Loosen the 2 clips and disconnect the 2 hoses. INSTALLATION Installation is in the reverse order of removal). HINT: After installation, check fluid level. Locations EFI Main Relay: Locations Engine Room R/B Page 4634 Fuse Block: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6539 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 5580 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5070 Page 1147 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 3753 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4754 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2808 O2S Application Table O2S Failure Threshold Charts Testing and Inspection Power Mirror Switch: Testing and Inspection Left side INSPECT MIRROR SWITCH INSPECTION Right side INSPECT MIRROR SWITCH INSPECTION If continuity is not as specified, replace the switch. Page 5869 Wheel Opening Moulding Page 2556 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 4218 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. ^ 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. ^ 09710-28012-01 (09710-07031) ^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 3220 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 352 Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT 11. REINSTALL THROTTLE BODY COVER A/T - Fluid Requirements Fluid - A/T: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information Page 3966 6. INSPECT LIMIT SWITCH CONTINUITY a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the transfer shift lever and after checking the operating sound, disconnect the connector and inspect the continuity between each terminal. HINT: When shifting the actuator fork shaft, connect the connectors. 7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check the combination meter. 9. INSPECT 4WD CONTROL ECU Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side connector from the back side. Page 1590 Required SSTs Radiator Cap Identification Procedure 1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating. 2. Proceed to the required inspection procedure for the radiator cap and kPa rating. Radiator Cap Inspection Procedure Type: N-cap, 88 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) Page 4665 Relay Box: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 753 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction directed by an arrow. b. Lock of the connectors is released, then disconnect the connectors. HINT: Be sure to hold both flank sides of the outer. If holding the top or bottom sides, it will obstruct disconnection. CONNECTION a. Align the male connector (on the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. c. Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.). HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. Page 6741 Brake Light Switch: Pinout Values and Diagnostic Parameters ABS A6, A7 ABS SPEED SENSOR FRONT LH, RH 1 - 2 : 1.40 - 1.80 kOhms (20°C, 68°F) A19 ABS SPEED SENSOR REAR 1 - 2 : 0.89 - 1.29 kOhms (20°C, 68°F) 3 - 4 : 0.89 - 1.29 kOhms (20°C, 68°F) A5 ABS ACTUATOR WITH ECU 6 - GROUND : 10 - 14 volts with ignition SW at ON or ST position 24 - GROUND : 10 - 14 volts with stop light SW on (Brake pedal depressed) 2, 18 - GROUND : Always continuity S4 STOP LIGHT SW 2 - 1 : Closed with brake pedal depressed Locations Impact Sensor: Locations Front Airbag Sensor Page 5449 Step 5 INSPECTION PROCEDURE Page 1330 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 2754 CHART 7 Page 6308 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6336 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. DISCONNECT CONNECTOR 3. RUN ENGINE AT APPROX. 2,000 rpm 4. SET BLOWER SPEED CONTROL SWITCH TO "HI" POSITION 5. SET TEMPERATURE CONTROL LEVER TO "MAX. COOL" POSITION 6. A/C SWITCH ON 7. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 4605 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 205 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 1642 REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE TIMING BELT 3. REMOVE NO.2 IDLER PULLEY Page 1195 Connecting Rod: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 2592 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 2185 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 8. REINSTALL INTAKE AIR CONNECTOR 9. REFILL WITH ENGINE COOLANT 10. REINSTALL THROTTLE BODY COVER Page 2328 Terminals Of ECU - Connector Pinouts (Part 1) Intake Manifold Assembly Intake Manifold: Specifications Intake Manifold Assembly Intake Manifold Upper Maximum Warpage ................................................................................................................... .................................................................... 0.15 mm Lower Maximum Warpage ............................... ........................................................................................................................................................ 0.15 mm Intake Manifold W/ Bolts and Nuts Torque .......................................................................................... ............................................................................................................................... 18 Nm Page 5724 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 5253 3. REMOVE HEATER CONTROL HOUSING a. Remove the 5 screws. b. Remove the heater control housing. 4. REMOVE INTEGRATION CIRCUIT a. Disconnect the 2 connectors. b. Remove the circuit. 5. REMOVE LENS Release the 3 claws, then remove the lens. REASSEMBLY 1. INSTALL LENS Install the lens. Page 3377 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 3457 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 6513 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 597 Applicable Vehicles Page 6357 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2802 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 2988 4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe. 5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. 6. Check if there is any fuel leakage. h. Observe these precautions when handling nylon tube. 1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by bending it. i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 4986 2. Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. 3. Press the SST activation switch and deploy the air-bag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. h. Dispose of the steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Deployment When Scrapping Vehicle DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a steering wheel pad with an airbag deployed in a collision, follow the same procedure given in step (d) in "AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE". CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. Page 5312 Refrigerant: Fluid Type Specifications Type R-134a Page 620 CHART 12 CHART 13 System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given. a. Check the heated oxygen sensors operation. b. See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 2038 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. A/C - Insufficient Cabin Cooling Heater Control Valve: Customer Interest A/C - Insufficient Cabin Cooling HEATING & AIR CONDITIONING AC004-04 May 20, 2004 Title: POOR PERFORMANCE OF A/C SYSTEM Models: '01 - '04 Sequoia & '00 - '04 Tundra May 20, 2004 Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to correct the condition. Applicable ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change Effective VINs shown below. ^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 3351 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 3904 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 486 Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT 11. REINSTALL THROTTLE BODY COVER Page 4951 Steering Gear: Service and Repair Disassembly and Reassembly Airbag - Inspection & Replacement After Collision Repairs and Inspections Required After a Collision: Technical Service Bulletins Airbag - Inspection & Replacement After Collision COLLISION REPAIR INFORMATION CRIB110 TITLE: SRS AIRBAG COMPONENT REPLACEMENT SECTION: ELECTRICAL BULLETIN # 110 MODELS: TOYOTA DATE: The SRS Airbag system is an important safety feature of Toyota vehicles. It supplements the vehicle seat belt system by providing additional protection to vehicle occupants in the event of a severe frontal or side collision (it equipped with side airbags). In order to assure correct system operation it is necessary to replace certain components of the airbag system following a collision. In order to assist technicians in determining which components should be inspected tested or replaced the repair manual information has been organized in the attached matrix and replacement notes. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, and side airbag sensor assembly should be inspected and diagnostic tests should be performed. Always refer to the Toyota service repair manual for the correct diagnostic and repair procedures. The attached SRS airbag component replacement information includes: ^ A matrix indicating components requiring replacement inspection or testing after the deployment of the driver and/or passenger SRS airbag. ^ Component replacement notes. CAUTION: SRS Airbag service work can only be performed AFTER 90 seconds from the time the ignition switch is turned to the "lock" position and the negative (-) terminal cable is disconnected from the battery. Page 4013 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR 2. REMOVE SPEED SENSOR (a) Remove the 2 clamp bolts, clamp nut and 5 resin clips holding the sensor wire harness from the axle and the fuel tank. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) HINT: When installing the rear sensor wire harness, never use the removed resin clips, which are service parts. - When replacing clips, set up new resin clips at the same angle of the removed resin clips. (b) Remove the bolt and speed sensor from the axle carrier. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check speed sensor signal. Page 5795 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Locations Fuel Pump Resistor Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 3160 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Page 1964 A/F and 02 Sensor Identification Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3236 Transmission Mode Indicator - A/T: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2883 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Locations Daytime Running Lamp Relay: Locations Instrument Panel Page 2631 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Electrical Specifications Resistance Page 3234 Glossary Of Terms And Symbols (Part 1) Page 4863 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE engine: Remove the air cleaner assembly. b. 2UZ-FE engine: Remove the air cleaner assembly with air cleaner hose. c. Disconnect the pressure feed tube from the PS vane pump. d. Connect Special Service Tool (SST), as shown in the illustration. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check that the valve of the SST is in the open position. e. Bleed the power steering system. f. Start the engine and run it at idle. g. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) h. With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: ^ Do not keep the valve closed for more than 10 seconds. ^ Do not let the fluid temperature become too high. i. With the engine idling, open the valve fully. Description and Operation Braking Sensor/Switch: Description and Operation Stop Light Switch This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. Engine - Accessory Drive Belt Squealing Noise Drive Belt: Customer Interest Engine - Accessory Drive Belt Squealing Noise ENGINE EG026-06 REVISED Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '06 Tundra April 21, 2006 TSB REVISION NOTICE: ^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered. Previous versions of this TSB should be discarded. Introduction Some customers may experience an abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor bracket, and revised installation procedure have been developed to address this condition. Applicable Vehicles ^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Parts Information Warranty Information Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection 5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire harness side connector. Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 6529 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4054 21. 4WD: Using the following SSTs and a press, install the bearing spacer. SST P/N: 09950-60010 (09951-00650) SST P/N: 09950-70010 (09951-07150) 22. 4WD: Install new oil seal (inside). A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). SST P/N: 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. Install steering knuckle. A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. Connect the lower ball joint to the steering knuckle with 4 bolts. Page 2848 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 4985 2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. f. Cover the steering wheel pad with a cardboard box or tires. - Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box. Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire - If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. - Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimension- Width: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTE: The tires may be marked by the airbag deployment, so use the redundant tires. g. Deploy the airbag. 1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. Page 5956 Page 2812 CHART 7 Page 4990 HINT: Have a battery ready as the power source to deploy the airbag. a. Remove the steering wheel pad. CAUTION: When storing the steering wheel pad, keep the upper surface of the pad facing upward. b. Using a service-purpose wire harness, tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 Sq.mm or more (0.0019 Sq.in.. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 Sq.mm (0.0019 Sq.in). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4 1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35.0 mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTE: Tighten the bolts by hand until the bolts become difficult to turn. - Do not tighten the bolts too much. Page 5562 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 4521 6. Select CHARGING from the Main Menu screen and press the SELECT soft key. 7. Select DIAGNOSTIC from the Charge Menu screen and press the SELECT soft key. 8. Select IN VEHICLE and press the NEXT soft key. 9. Select MODEL and press the NEXT soft key. NOTE: ^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad. ^ "MODEL" and "STOCK # " are linked to custom algorithms and are the most accurate testing procedures. Page 1124 Driver Side J/B And Integration Relay Inner Circuit Page 4923 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4347 B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. NOTE: Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of brake vibration on this vehicle. G. Determine if TSB BROO4-02 has already been performed. Repair Procedure No. 1 1. Remove the front wheel. 2. 2WD: Using a screwdriver and hammer remove the grease cap. 3. 4WD: Disconnect drive shaft. A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. Locations Hydraulic Control Assembly - Antilock Brakes: Locations Engine Compartment Page 2098 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Page 2340 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2794 Page 2214 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4834 Page 4222 Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. ^ 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 2135 Spark Plug: Application and ID Recommended Spark Plugs DENSO K20R-U NGK BKR6EYA Page 2075 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 215 Terminals Of ECU - Connector Pinouts (Part 1) Page 6117 * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type: Power Adjuster) section of the applicable service manual. 2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the location shown below. 3. Reassemble the front seat with the new seat cushion cover. NOTE: Do not use air tools when installing the seat assembly back into the vehicle. Diagram Information and Instructions Transmission Mode Indicator - A/T: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2272 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Initial Inspection and Diagnostic Overview Cruise Control: Initial Inspection and Diagnostic Overview Cruise Control System Check Sheet Page 2905 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 5005 Testing and Inspection Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Four Wheel Drive Selector Relay; Testing and Inspection; Procedures. Page 4031 4. CHECK PEDAL RESERVE DISTANCE Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbs: More than 95 mm (3.74 inch) If the reserve distance is incorrect, troubleshoot the brake system. Page 5502 A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration. HINT: Preventing the seat belt from retraction with a clip will make the following work easier. B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped side to the anchor. C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by moving the Velcro tape several times as shown in the illustration. NOTE: Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly. 2. INSTALL FLUOROCARBON RESIN TAPE A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration. NOTE: Page 1431 Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the slide rheostat, then read the rheostat indication. If resistance value is not as specified, replace the engine coolant sender gauge. Page 2541 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Seat Belt Tongue Plate Stopper Seat Belt: Service and Repair Seat Belt Tongue Plate Stopper NOTE: The content of this article/image reflects the changes identified in TSB BO017-07. Introduction A new service part for the seat belt tongue plate stopper has been introduced. Installation procedures are provided to supplement the Repair Procedures. Installation Procedure 1. Preparation A. Shift the tongue plate to the upper portion of the tongue plate stopper, and temporarily hold it with a clip or tape. B. Remove any pieces of the original tongue plate stopper in the webbing, with a pair of pliers. CAUTION: Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MUST be replaced if: - The webbing is cut, frayed, worn, or damaged. - It has been used in a severe impact. Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to damage the webbing during repair. 2. Install the NEW tongue plate stopper A. Install a NEW tongue plate stopper in the hole of the webbing. NOTE: Be sure to install the stopper in the correct direction as shown in the illustration. Page 3291 a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4 switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and the 4HI indicator lights come on when the touch select high-low switch is in OFF position. HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position. - If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash. 3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals. Touch select 2-4 switch Touch select high-low switch: If continuity is not as specified, replace the center integration panel assembly. 4. INSPECT ACTUATOR RESISTANCE a. Using an ohmmeter, measure the resistance between terminals 1 and 2. Standard resistance: 0.3 - 100 Ohms b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground. Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the actuator assembly. Page 1789 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 101 Driver Side J/B And Integration Relay Engine - Accessory Drive Belt Squealing Noise Drive Belt Tensioner: All Technical Service Bulletins Engine - Accessory Drive Belt Squealing Noise ENGINE EG026-06 REVISED Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '06 Tundra April 21, 2006 TSB REVISION NOTICE: ^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered. Previous versions of this TSB should be discarded. Introduction Some customers may experience an abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor bracket, and revised installation procedure have been developed to address this condition. Applicable Vehicles ^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Parts Information Warranty Information Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 5299 Refrigerant Line (Part 2) Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 3902 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5295 Heater Core Case: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE HEATER RADIATOR a. Remove the 5 screws and 3 clamps. b. Pull out the heater radiator. c. Remove the 2 screws and 2 clips, then disconnect the heater radiator pipes. 2. REMOVE AIR VENT DUCT Remove the 2 screws and duct. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 7025 ^ Using wipers instead of an ice scraper to remove frost and ice from the windshield during a car warm up can dull, nick, or tear the rubber. ^ Banging wiper on the glass to remove ice & snow can cause the blade to bend and rubber to come out of the blade providing the potential to scratch the glass. ^ Ice forms in wiper blade pin joints, which causes streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber with your hand to loosen the frozen joints. To prevent this condition, use winter blades with a rubber cover. Page 2326 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 2671 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 4603 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2426 CHART 11 Page 3767 Transmission Mode Indicator - A/T: Testing and Inspection ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 4, 7, 8 - GROUND : Approx. 13 Ohms O4 O/D MAIN SW 3 - 1 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S4 STOP LIGHT SW 1 - 2 : Closed with brake pedal depressed E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position S2, SL - E1 : 0 - 1.5 volts with vehicle not move STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F) OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F) VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with ignition SW on and throttle valve fully open VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off SPD - E1 : Pulse generation with vehicle moving 2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position +B - E1 : 9 - 14 volts with ignition SW at ON or ST position BATT - E1 : Always 9 - 14 volts P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever in 2 position 3 - 8 : Closed with shift lever in L position Page 802 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Page 6304 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 3310 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 6608 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2682 Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT 11. REINSTALL THROTTLE BODY COVER Page 394 Key Reminder Switch: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 5733 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2532 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Service and Repair Hood Shock / Support: Service and Repair HOOD SUPPORT REPLACEMENT 1. REMOVE HOOD SUPPORT a. Remove the bolt and hood support from the hood. HINT: While supporting the hood by hand, remove the hood support from the hood. b. Remove the bolt and hood support. 2. IF NECESSARY, REPLACE HOOD SUPPORT NOTE: Handling the hood support Do not disassemble the support as the cylinder is filled with pressurized gas. - If the hood support is to be replaced, drill a 2.0 - 3.0 mm (0.079 - 0.118 in.) hole in the area shown in the illustration to completely release the high pressure gas before disposing of it. - When drilling, chips may fly out so work carefully. - The gas is colorless, odorless and non-toxic. - When working, handle the hood support carefully. Never score or scratch the exposed part of the piston rod, and allow any paint or oil to get on it. - Do not turn the piston rod and cylinder with the hood support fully extended. 3. INSTALL HOOD SUPPORT a. Install the bolt and hood support to the body. Torque: 22 N.m (224 kgf.cm, 16 ft.lbf) b. Install the bolt and hood support to the hood. Torque: 22 N.m (224 kgf.cm, 16 ft.lbf) Page 3541 ^ Torque the bolts to the specification found in the applicable Repair Manual. NOTE In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the torque converter to the flywheel assembly. Specifications Firing Order: Specifications Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2 Page 5063 Page 5763 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 4115 Repair Procedure 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. Page 5867 Lower Side Moulding / Trim: Diagrams Body Outside Moulding Page 3690 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 2WD: INSTALL GREASE CAP 8. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Lightly strike the SST on its circumference evenly. b. Coat MP grease to the oil seal lip. Page 567 Service and Repair Universal Joint: Service and Repair SPIDER BEARING REPLACEMENT 1. PLACE MATCHMARKS ON SHAFT AND YOKE 2. REMOVE SNAP RING a. Using a brass bar and hammer, slightly tap in the bearing outer race. b. 4WD rear propeller shaft: Using 2 screwdrivers, remove the 4 snap rings from the grooves. c. 2WD and 4WD front propeller shaft: Using needle nose pliers, remove the 4 snap rings from the grooves. 3. REMOVE SPIDER BEARING a. Using SST, push out the bearing from the flange yoke. SST 09332-25010 HINT: Sufficiently raise the part indicated by "A" so that it does not come into contact with the bearing. b. Clamp the bearing outer race in a vise and tap off the flange with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. c. Install the 2 removed bearing outer races to the spider, and clamp them in a vise. d. Using SST, push out the bearing from the sleeve yoke. SST 09332-25010 e. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * 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 systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 3722 ^ Torque the bolts to the specification found in the applicable Repair Manual. NOTE In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the torque converter to the flywheel assembly. Page 531 A/F and 02 Sensor Identification Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1926 Page 1345 Oil Pressure Gauge: Testing and Inspection INSPECT OIL PRESSURE GAUGE RESISTANCE Measure the resistance between terminals A and B. If resistance value is not as specified, replace the receiver gauge. Page 1108 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 6324 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4294 Required SSTs Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. Page 6730 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1050 (b) In this position. check the rear brake pressure If the measured value is not within the standard, replace the valve body. Page 6099 INSPECT FRONT TILT MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the seat adjuster. INSPECT FRONT TILT MOTOR PTC THERMISTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (-) lead to the battery negative (-) terminal, then move the seat cushion to the highest position. b. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. c. Disconnect the leads from the terminals. d. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the seat cushion begins to descend. If operation is not as specified, replace the seat adjuster. INSPECT LIFTER MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the seat adjuster. INSPECT LIFTER MOTOR PTC THERMISTOR OPERATION Page 6189 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 5511 Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to damage the webbing during repair. 3. Install the NEW tongue plate stopper A. Install a NEW tongue plate stopper in the hole of the webbing. NOTE Be sure to install the stopper in the correct direction as shown in the illustration. B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small "C" clamp. NOTE To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to moderate clamping force when crimping the two halves of the tongue plate stopper together. HINT Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel to each other. Page 1585 Install the 2 radiator supports, 2 bushings and 2 pipes with the 4 bolts. Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.) 8. INSTALL RADIATOR CAP INSTALLATION 1. INSTALL NO.1 FAN SHROUD Install the No.1 fan shroud with the 4 bolts Torque: 5 Nm (50 kgf-cm, 44 inch lbs.) 2. INSTALL RADIATOR ASSEMBLY a. Set the radiator bracket hooks to the radiator support holes. b. Install the 4 bolts. Torque: 12 Nm (120 Nm, 9 ft. lbs.) 3. INSTALL NO.2 FAN SHROUD Install the No.2 fan shroud with the 2 clips. 4. CONNECT A/T OIL COOLER HOSES TO RADIATOR 5. CONNECT UPPER RADIATOR HOSE TO RADIATOR 6. CONNECT LOWER RADIATOR HOSE TO RADIATOR 7. CONNECT RADIATOR RESERVOIR HOSE TO RADIATOR 8. FILL WITH ENGINE COOLANT 9. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 10. RECHECK ENGINE COOLANT LEVEL 11. INSTALL ENGINE UNDER COVER Page 180 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 6424 Glossary Of Terms And Symbols (Part 2) Locations Vehicle Lift And Support Locations Page 2820 CHART 18 CHART 19 Page 4136 Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). ^ 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Page 3243 Transmission Mode Indicator - A/T: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1) Page 5564 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Diagrams Control Assembly: Diagrams Air Conditioning Control Assembly (Center Cluster Integration) Page 6260 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Testing and Inspection Four Wheel Drive Selector Switch: Testing and Inspection INSPECTION 1. INSPECT 2WD -> 4HI SHIFT a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4 switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4 switch is in OFF position. HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be moved back and forth. - If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash. 2. INSPECT 4HI -> 4LO SHIFT Page 5808 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3068 Fuel Pump Relay: Testing and Inspection Circuit Opening Relay CIRCUIT OPENING RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN) 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL RELAY BOX COVER Page 3761 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3844 c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 4LO position. d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO -> 4HI position. HINT: When inspecting the operation described, use a heater main relay. NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing. Specifications Timing Belt Idler Pulley: Specifications Torque Specifications No.1 Idler Pulley .................................................................................................................................. .................................................................... 34.5 Nm No.2 Idler Pulley ............................................... ....................................................................................................................................................... 34.5 Nm Page 2324 Locations Airbag Sensor Assembly: Locations Instrument Panel Page 5761 Splice Location B11 Page 545 Locations Instrument Panel Page 5815 Trailer Connector: Testing and Inspection TRAILER TOWING T6 TRAILER SOCKET 2 - GROUND : Approx. 12 volts with light control SW at TAIL or HEAD position 1 - GROUND : Approx. 12 volts with ignition SW at ON position and shift level in R position 4 - GROUND : Always continuity Page 3295 STANDARD VALUE OF ECU TERMINAL Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 4900 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTE: Page 1829 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. DISCONNECT CONNECTOR 3. RUN ENGINE AT APPROX. 2,000 rpm 4. SET BLOWER SPEED CONTROL SWITCH TO "HI" POSITION 5. SET TEMPERATURE CONTROL LEVER TO "MAX. COOL" POSITION 6. A/C SWITCH ON 7. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 4691 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2429 CHART 15 Page 3630 Standard resistance: More than 0.5 M ohms If the resistance value is not as specified, replace the actuator assembly. 2. INSPECT A.D.D. ACTUATOR OPERATION Apply battery positive voltage between the terminal 2 or 6, and check the actuator operation by sound, A.D.D. status and continuity between the terminal 3 and 4. If the operation is not as specified, replace the actuator assembly. 3. INSPECT LIMIT SWITCH CONTINUITY a. Connect the actuator connector. b. Shift the transfer shift lever or switch the transfer operation switch to "H2" position. c. Check the A.D.D. actuator operation by sound. d. Disconnect the actuator connector. e. Check the continuity between each terminal, as shown in the chart. f. Connect the actuator connector. g. Shift the transfer shift lever or switch the transfer operation switch to "H4" position. h. Check the A.D.D. actuator operation by sound. i. Disconnect the actuator connector. j. Check the continuity between each terminal, as shown in the chart. k. Connect the actuator connector. Page 5976 Wire Harness Fuse Location Troubleshooting Procedure Page 570 Page 5260 Evaporator Case: Testing and Inspection On-Vehicle Inspection COOLING UNIT ON-VEHICLE INSPECTION 1. INSPECT FOR LEAKAGE OF REFRIGERANT a. Remove the glove compartment door. b. Remove the lower No.2 finish panel. c. Remove the lower center cover. d. Remove the lower LH finish panel. e. Remove the lower cover. f. Remove the blower resistor. 1. Disconnect the connector. 2. Remove the 2 screws and blower resistor. g. Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints or check the evaporator. h. Install the blower resistor with the 2 screws. i. Install the lower cover. j. Install the lower LH finish panel. k. Install the lower center cover. l. Install the lower No.2 finish panel. m. Install the glove compartment door. 2. INSPECT EXPANSION VALVE a. Check quantity of gas during refrigeration cycle. b. Set on manifold gauge set. c. Run engine. 1. Run the engine at 1,500 rpm for at least 5 minutes. 2. Then check that the high pressure reading is 1.37 - 1.57 Mpa (14 - 16 kgm/sq.cm, 199 - 288 psi). d. Check expansion valve. If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/sq.cm, 0 psi). HINT: When the lower pressure drop to 0 kPa (0 kgf/sq.cm, 0 psi), feel the receiver's IN and OUT sides for no temperature difference. Page 6410 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 5277 4. Cycle the temperature control knob several times and confirm proper water control valve adjustment. Diagram Information and Instructions Seat Belt Reminder Buzzer: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2871 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 6269 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1289 Assenmacher Specialty Tools 1-800-525-2943 Page 5152 8. REMOVE STEERING KNUCKLE a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION 1. INSTALL STEERING KNUCKLE a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTICE: Be careful not to damage the oil seal and drive shaft boot. b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm (1,100 kgf-cm, 77 ft. lbs.) 2. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER a. Install the disc, brake caliper and 2 bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) b. Install the brake line clamp to the steering knuckle with bolt. Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.) 5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.) 6. 4WD: INSTALL DRIVE SHAFT LOCK NUT a. While applying the brakes, tighten the nut. Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.) b. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 9. DEPRESS BRAKE PEDAL SEVERAL TIMES 10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL Disassembly and Reassembly Page 3908 Transmission Mode Indicator - A/T: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 5248 b. Set the temperature control dial at "MAX. COOL" position. c. Adjust mode control cable. Pull the air inlet control link to "FACE" position, connect the control cable and lock the clamp. HINT: Lock the clamp during lightly pulling the outer cable in the direction, as shown in the illustration by an arrow. d. Adjust air mix control cable. Pull the air inlet control link to "COOL" position, connect the control cable and lock the clamp. HINT: Lock the clamp during lightly pushing the outer cable in the direction as shown in the illustration by an arrow. e. Adjust water valve control cable. Pull the air inlet control link to "COOL" position, connect the control cable and lock the clamp. HINT: Lock the clamp during lightly pushing the outer cable in the direction, as shown in the illustration by an arrow. 3. INSTALL HEATER TO REGISTER DUCT NO.4 4. INSTALL LOWER NO.2 FINISH PANEL 5. INSTALL GLOVE COMPARTMENT PANEL 6. INSTALL HEATER TO REGISTER DUCT NO.2 7. INSTALL LOWER LH FINISH PANEL Page 2669 Camshaft Position Sensor Page 1917 CHART 8 CHART 9 Page 239 Terminals Of ECU - Connector Pinouts (Part 2) INSPECTION 1. REMOVE ECM 2. INSPECT ECM 3. REINSTALL ECM Page 2594 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 4369 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: Page 5424 Impact Sensor: Service and Repair Removal and Installation Front Airbag Sensor REMOVAL NOTE: - If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded. - Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. - Never reuse the sensor involved in a collision when the SRS has deployed. - Never repair a sensor in order to reuse it. Page 5447 Steps 1 - 3 Page 3379 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Page 5952 Page 895 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER Remove the 9 bolts, seal washers and cylinder head cover. 7. REMOVE LH CYLINDER HEAD COVER a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal washers and cylinder head cover. 8. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360°) and align the mark. 9. INSPECT VALVE CLEARANCE Page 5920 Specifications Wheel Cylinder: Specifications Wheel Cylinder Mounting Bolts 10 Nm Hydraulic Brake Line 15 Nm Instruments - Coolant Temperature Gauge Inaccurate Temperature Gauge: All Technical Service Bulletins Instruments - Coolant Temperature Gauge Inaccurate ELECTRICAL EL009-01 October 12, 2001 Title: TEMPERATURE GAUGE INACCURATE Models: '00 - '01 Tundra Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the engine coolant temperature gauge displays an abnormally high reading during normal engine operating temperatures. To address this condition, an updated Temperature Gauge has been made available. Applicable Vehicles ^ 2000 - 2001 model year Tundra trucks, built prior to the VIN shown. Production Change Information Parts Information Repair Procedure IMPORTANT: Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the temperature gauge. 1. Remove the four bolts securing the combination meter assembly. 2. Replace the Temperature Gauge. 3. Reassemble the combination meter. Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 2376 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system/components or in the powertrain control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the DTCs remain recorded in the ECM memory. Page 4252 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 6881 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Testing and Inspection Seat Sensor/Switch: Testing and Inspection Passenger's seat only: INSPECT SEAT BELT WARNING OCCUPANT DETECTION SENSOR CONTINUITY Check that continuity exists between the terminals 1 and 2 when pressing the sensing part. If operation is not as specified, replace the sensor. Page 2471 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 1707 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 2243 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 5197 Blower Motor: Testing and Inspection Blower Unit INSPECTION INSPECT AIR INLET SERVOMOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 3. b. Check the motor arm rotates counterclockwise and arm stops on the "FRESH" position. c. Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 1. d. Check the motor arm rotates counterclockwise and arm stops on the "RECIRC" position. Page 5423 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction directed by an arrow. b. Lock of the connectors is released, then disconnect the connectors. HINT: Be sure to hold both flank sides of the outer. If holding the top or bottom sides, it will obstruct disconnection. CONNECTION a. Align the male connector (on the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. c. Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.). HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. Page 93 Relay Box: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4775 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2663 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 6984 Windshield: Service and Repair REMOVAL 1. REMOVE INNER REAR VIEW MIRROR Remove the inner rear view mirror as shown in the illustration. 2. REMOVE ASSIST GRIPS a. Using a screwdriver, remove the caps. HINT: Tape the screwdriver tip before use. b. Driver's side: Using a torx driver, remove the 2 torx screws and assist grip. Torx driver: T30 (Part No.09041-00030 or locally manufactured tool) c. Passenger's side: Using a torx driver, remove the 4 torx screws and 2 assist grips. Torx driver: T30 (Part No.09041-00030 or locally manufactured tool) 3. REMOVE FRONT PILLAR GARNISH a. Using a screwdriver, remove the front pillar garnish. HINT: Tape the screwdriver tip before use. b. Employ the same manner described above to the other side. 4. REMOVE SUN VISORS Page 747 Impact Sensor: Description and Operation FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled. Page 5961 A. AFFECTED VIN RANGE III. Preparation A. PARTS ^ No parts are required for the inspection. B. EQUIPMENT & MATERIALS ^ Protective eyewear ^ Standard heater core hose Page 4952 Page 3279 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Locations Steering Wheel: Locations Steering Wheel Pad And Spiral Cable Page 5561 Seat Belt Reminder Buzzer: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 4996 Steering Wheel: Service and Repair Replacement Requirements REPLACEMENT In the following cases, replace the steering wheel pad, steering wheel or spiral cable. CAUTION: For removal and installation of the steering wheel pad, and be sure to follow the correct procedure. Page 4810 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 132 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 2897 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4465 (a) Set the SST on the master cylinder, and lower the pin until its tip slightly touches the piston. SST 09737-00011 (b) Turn the SST upside down, and set it on the booster. SST 09737-00011 (c) Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 inch) (d) Using SST, adjust the booster push rod length until the push rod lightly touches the pin head. SST 09737-00020 4. INSTALL MASTER CYLINDER 5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 6. CHECK FOR FLUID LEAKAGE 7. CHECK AND ADJUST BRAKE PEDAL 8. DO OPERATIONAL CHECK Page 2320 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals with the switch ON (switch pin released). b. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 6566 B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Page 5356 - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Locations Page 1980 CHART 7 Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 94 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3525 b. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the 3 clamps with the 3 bolts. 7. FILL ATF AND CHECK FLUID LEVEL Page 3807 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Page 1839 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Page 1487 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 6219 e. Inspect the RES (resume) switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset. - Depress the brake pedal. - Shift into except D position. - Pull the cruise control switch for CANCEL. 4. After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed before the cancellation. Page 3180 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Page 4150 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front hub bearing play is within the specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the hub nuts and disc. Reinstall the disc 1/6 of a turnround from its original position on the hub. Install and torque the hub nuts. Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) (b) Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. (c) Repeat (a) and (b) until the disc has been installed on the 4 remaining hub positions. If the minimum runout recorded in (a) to (c) is less than the maximum disc runout, install the disc in that position. If the minimum runout recorded in (a) to (c) is greater than the maximum disc runout, replace the disc and repeat step 3. REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap tease glycol grease end disc brake grease to the parts indicated by the arrows. Page 1996 CHART 24 Page 5342 Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a. Do a diagnostic system check. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. - Check cuts and cracks in wire harnesses, and chipping in connectors. - Check the deformation of the horn button contact plate on the steering wheel pad. HINT: If the horn button contact plate of the steering wheel pad is deformed, never repair it. Always replace the steering wheel pad with a new one. - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED a. Do a diagnostic system check. b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check the deformation on the horn button contact plate of the steering wheel. - Check the damage on the spiral cable connector and wire harness. HINT: Page 1990 Page 90 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4878 a. Using a micrometer, measure the height, thickness and length of the 10 plates. Minimum height: 8.6 mm (0.339 inch) Minimum thickness: 1.397 mm (0.0550 inch) Minimum length: 14.991 mm (0.5902 inch) b. Using a feeler gauge, measure the clearance between the rotor groove and plate. Maximum clearance: 0.033 mm (0.0013 inch) If it is more than the maximum, replace the plate and/or rotor with one having the same mark stamped on the cam ring. Inscribed mark: 1, 2, 3, 4 or None HINT: There are 5 vane plate lengths with the rotor and cam ring marks: 3. INSPECT FLOW CONTROL VALVE Page 6188 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 6363 Clock: Pinout Values and Diagnostic Parameters I24 (A), I25 (B) INTEGRATION CONTROL AND PANEL (B) 5 - GROUND : Always approx. 12 volts (Power for clock) (B) 13 - GROUND : Approx. 12 volts with ignition SW at ON or ACC position (Power for indication) (A) 7 - GROUND : Approx. 12 volts with light control SW at TAIL or HEAD position (Signal of indication) (B) 1 - GROUND : Always continuity Page 2751 CHART 1 Page 3332 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 4324 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 613 CHART 1 Page 5910 II. Identification of Affected Vehicles Page 2053 Voltage: 4.2 - 4.8 V d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor. Page 4095 4. With ABS: Disconnect ABS speed sensor and wire harness clamp from steering knuckle. Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. Disconnect brake line. Using the following SST, disconnect the brake line. Use a container to catch the brake fluid. SST P/N: 09023-00100 6. Remove brake caliper and disc. A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper, and disc. 7. Remove shock absorber. Page 2748 Page 2653 Page 220 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Vehicle - Long Term Storage Guidelines Paint: Technical Service Bulletins Vehicle - Long Term Storage Guidelines T-SB-0079-09 Rev1 March 4, 2009 Long Term Vehicle Storage Guidelines Service Category General Section Maintenance Market USA Applicability December 23, 2009 Rev1: TSB REVISION NOTICE ^ Applicability has been updated to include 2010 Prius PHV model and 2011 vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Long-term or off-site storage requires special care to keep vehicles factory fresh and ready for delivery. The following guidelines should be performed to minimize vehicle component/part degradation due to extended vehicle storage conditions. Long-term storage can affect a vehicle's systems and components. Any problems that are found should be corrected immediately. Required Tools & Equipment Warranty Information Procedure Page 2247 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 3612 Valve Body: Service and Repair Upper Valve Body 1. COMPONENTS 2. SPRING AND RETAINER Page 3113 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 5401 HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY NOTE: - When disposing of the steering wheel pad (with airbag) only, never use the customers vehicle to deploy the airbag. - Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. a. Remove the steering wheel pad. CAUTION: When storing the steering wheel pad, keep the upper surface of the pad facing upward. b. Remove the steering wheel pad connector. Remove the connector on the rear surface of the steering wheel pad from the bracket. Page 3445 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 179 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 2052 Evaporative Vapor Pressure Sensor: Testing and Inspection VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under these conditions: 1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor. Page 3201 Spark Plug: Application and ID Recommended Spark Plugs DENSO K20R-U NGK BKR6EYA Page 3912 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Specifications Brake Master Cylinder: Specifications Brake Master Cylinder Reservoir Retaining Screw 1.8 Nm Retaining Bracket 13 Nm Hydraulic Brake Lines 15 Nm Piston Stopper Bolt 10 Nm Page 2901 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1253 Valve Spring Shim: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Valve Clearance; Testing and Inspection. Page 599 Engine Bank Identification Ground Locations Seat Belt Reminder Buzzer: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ...................................................... 1,324 kPa or More Minimum Pressure ......................................... ........................................................................................................................................................... 981 kPa Difference Between Each Cylinder ........................................................................................ ......................................................................... 98 kPa or Less Page 3095 Throttle Body: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 4831 Page 2634 Glossary Of Terms And Symbols (Part 2) Page 543 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 5730 Glossary Of Terms And Symbols (Part 2) Page 4835 Page 4693 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 711 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 2016 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 3898 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 5344 AIRBAG SENSOR FRONT INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Description and Operation Data Link Connector, A/T: Description and Operation The vehicle's ECM uses the V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W. format. Page 4639 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 5574 Seat Belt Reminder Buzzer: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6547 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 4961 c. Expand a new teflon ring with your fingers. NOTICE: Be careful not to over-expand the teflon ring. d. Coat the teflon ring with power steering fluid. e. Install the teflon ring to the steering rack, and settle it down with your fingers. 5. IF NECESSARY, REPLACE TEFLON RINGS a. Using a screwdriver, remove the 4 teflon rings from the control valve assembly. NOTICE: Be careful not to damage the grooves for the teflon ring. b. Expand 4 new teflon rings with your fingers. NOTICE: Be careful not to overexpand the teflon ring. c. Coat the teflon rings with power steering fluid. d. Install the teflon rings to the control valve assembly, and settle them down with your fingers. e. Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve assembly. SST 09631-20081 NOTICE: Be careful not to damage the teflon rings. Page 4688 Glossary Of Terms And Symbols (Part 1) Page 399 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 6496 Audible Warning Device Control Module: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 4660 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 6494 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Locations Anti-Lock Brake System Page 1941 CHART 30 Page 5455 Supplemental Restraint System Page 2000 Page 4300 A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. SST P/N: 09950-60020 (09951-00810) SST P/N: 09950-70010 (09951-07150) 16. Install new bearing. A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. SST P/N: 09527-17011 SST P/N: 09950-60020 (09951-00910) B. Using snap ring pliers, install a NEW snap ring. 17. Install new oil seal (outside). A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). SST P/N: 09223-15030 Page 5770 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 6422 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 5633 Seat Belt Tensioner: Removal and Replacement SEAT BELT PRETENSIONER REMOVAL NOTE: - If the wiring connector of the seat belt pretensioner is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. - Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts. 1. Standard cab: REMOVE FRONT SEAT OUTER BELT a. Remove the 5 screws and front door scuff plate. b. Remove the front pillar garnish. 1. Using a screwdriver, remove the caps. HINT: Tape the screwdriver tip before use. 2. Using a torx driver, remove the torx screws and assist grip. Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool) 3. Using a screwdriver, remove the front pillar garnish. HINT: Tape the screwdriver tip before use. c. Using a screwdriver, remove the back panel upper garnish. Page 2877 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 3409 Data Link Connector, A/T: Testing and Inspection DLC 3 Inspection The vehicle's ECM uses the V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W. format. HINT: If your display shows "UNABLE TO CONNECT TO VEHICLE" when you have connected the cable of OBD II scan tool or TOYOTA hand-held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. If communication is normal when the tool is connected to another vehicle, inspect 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, so consult the Service Department listed in the tool's instruction manual. Page 6071 Page 4263 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 4429 Load Compensator: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE VALVE BRACKET (a) Remove the nut, washer, bolt and 2 plate washers. (b) Remove the 2 nuts, 2 washers, set plate and valve bracket from the valve body. 2. DISCONNECT SPRING FROM VALVE Using pliers, remove the clip, and remove the spring from the valve. Page 5131 e. Bend the spring clips. Using a hammer, bend the spring clips into the position. INSTALLATION 1. INSTALL LEAF SPRING Install the shackle and leaf spring with 3 bolts, washers and nuts. Torque: 170 Nm (1,735 kgf-cm, 125 ft. lbs.) HINT: After stabilizing the suspension, torque the nuts. 2. INSTALL U-BOLTS Install the spring bumper, spring seat and 2 U-bolts with the 4 washers and nuts. Torque: 133 Nm (1,350 kgf-cm, 98 ft. lbs.) HINT: Tighten the U-bolts so that the lengths of all the U-bolts under the spring seat are the same. 3. INSTALL REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 4. REMOVE SAFETY STANDS Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 2193 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Page 3913 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 3918 Transmission Mode Indicator - A/T: Description and Operation ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR SYSTEM OUTLINE The electronically controlled transmission electrically controls the, throttle pressure, lock-up pressure, and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls the gear shift timing and lock-up timing in response to the vehicle's driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection of the gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. GEAR SHIFT OPERATION When driving, the engine warm up condition is input as a control signal from the engine coolant temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA, VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. LOCK-UP OPERATION When the engine control module decides based on each signal that the lock-up condition has been met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the electronically controlled transmission solenoid to GROUND. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input to TERMINAL STP of the engine control module. As a result, the engine control module cuts the current to the solenoid to release the lock-up. 4. OVERDRIVE CIRCUIT - O/D main SW on When the O/D main SW is switched to ON position, a signal is input to TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range, through the control of the engine control module. - O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range through the control of the engine control module. When in the overdrive range already, shift down is made. Page 1812 Fuel Pump Relay: Testing and Inspection Circuit Opening Relay CIRCUIT OPENING RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN) 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL RELAY BOX COVER Page 182 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Locations Instrument Panel Page 3741 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Locations Fusible Link: Locations Driver Side J/B And Integration Relay Page 5935 II. Identification of Affected Vehicles Page 2435 CHART 22 Page 2758 CHART 12 CHART 13 Page 1637 Water Pump: Diagrams WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Part 1 of 3 Page 1324 Oil Cooler: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE OIL FILTER Page 2542 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 1800 Windows 2000 SP2 or later Windows XP Pro SP1 or later For more information about the J2534 devices listed above, contact the vendors. To report compatibility problems with listed hardware/software, please contact the device manufacturer. For more information about Toyota vehicle reprogramming CDs or to report problems running Toyota's Calibration Update Wizard software, please contact Toyota. OBTAINING A CALIBRATION CD The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the Calibration Update Wizard application software for a Windows PC, and instructions for use. Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N 00456-REPRG-001. IMPORTANT NOTICE It is possible to permanently damage a vehicle controller during the flash reprogramming process. It is especially important to understand that once started, the reprogramming process must not be interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go into standby, hibernation or similar power management modes. The information provided herein is intended expressly for use by qualified professional automobile technicians. To prevent damage to your customer's vehicle and ensure safe service practice, read these materials completely and thoroughly before servicing the vehicle and be sure to follow all instructions. Page 6429 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3608 5. REMOVE 29 BOLTS 6. REMOVE UPPER VALVE BODY WITH PLATE AS A SINGLE UNIT Hold the valve body plate to the upper valve body, and remove the upper valve body with the plate. NOTICE: Be careful that the check balls and strainer do not fall out. 7. REMOVE OIL STRAINER Remove the 3 oil strainers from the plate. 8. REMOVE CHECK VALVE AND SPRING 9. REMOVE 10 CHECK BALLS 10. REMOVE 2 GASKETS FROM PLATE REASSEMBLY Antenna - Loose Mast Antenna Mast: Customer Interest Antenna - Loose Mast AUDIO AU002-01 June 1, 2001 Title: ANTENNA MAST DURABILITY Models: '00 - '01 Tundra Introduction Some customers may experience a loose Tundra antenna mast due to the breakage of the antenna holder. A revised antenna holder assembly is available to resolve this issue. Applicable Vehicles ^ 2000 - 2001 model year Tundra vehicles. Production Change Information Parts Information Repair Procedure Replace antenna holder assembly. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1914 CHART 2 CHART 3 CHART 4 Page 2854 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Diagram Information and Instructions Clock: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 4801 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 6667 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 3315 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 1058 - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 575 CHART 28 Page 184 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 1985 CHART 14 Page 6094 NOTE:The body color code is on the vehicle Certification Regulation Label, located on the left front door "B" pillar or door rear lower surface. Page 4515 Battery: Technical Service Bulletins Electrical - Battery Maintenance and Testing PRODUCT GENERAL INFORMATION PG001-06 Title: BATTERY MAINTENANCE FOR IN-STOCK VEHICLES & PRE-DELIVERY Models: All Models & Model Years January 26, 2006 TSB REVISION NOTICE: ^ November 28, 2006: "Required SSTs" have been updated (SST P/N 00002-MCGR8 has been added). "Recommended Equipment" has been removed (superseded by SST P/N 00002-MCGR8). Screen prints and text have been updated in the "Battery Inspection Procedure". "Battery Service Procedure" has been renamed "Battery Inspection Results". Two sections have been added for SST P/N 00002-MCGR8: "Battery Charging Procedure" and "Battery Charging Results". PLEASE READ ENTIRE TSB. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. PG017-02. TSB No. PGO17-02 is now obsolete and should be discarded. Introduction A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include storage period, temperature, parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and optimal battery life. As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or failed batteries due to lack of maintenance. It is the dealer's responsibility to maintain the specified State of Charge (SOC) of the vehicle's battery while in stock and assure proper State of Charge (SOC) at delivery. To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dealers should check battery State of Charge (SOC) and recharge, if necessary, within 48 hours of delivery to customers. Applicable Vehicles ^ All models and model years. Warranty Information Page 1988 CHART 18 CHART 19 Page 3466 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 5737 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 63 Glossary Of Terms And Symbols (Part 1) Page 229 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1522 Coolant: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT a. Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. Remove the 3 drain plugs on the engine and radiator, and drain the coolant. c. Close the 3 drain plugs. Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.) for engine 3. REFILL WITH ENGINE COOLANT a. Slowly fill the system with coolant. ^ Use of improper coolants may damage engine cooling system. ^ Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the manufacturer's directions. ^ Use of the coolant which includes more than 50% [freezing protection down to -35°C (-31°F)] or 60% [freezing protection down to -50°C (-58°F)] of ethylene-glycol is recommended, but not more than 70%. NOTICE: ^ Do not use an alcohol type coolant or plain water alone. ^ The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity: 11.6 liters (12.3 US qts, 10.2 Imp. qts) b. Install the radiator cap. c. Bleed the cooling system. 1. Start the engine, and open the heater water valve. 2. Maintain the engine speed at 2,000 - 2,500 rpm, and warm up the engine. d. Stop the engine, and wait until the engine coolant cools down. e. Refill coolant into the reservoir until it is "FULL". 4. CHECK FOR ENGINE COOLANT LEAKS 5. CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY 6. REINSTALL ENGINE UNDER COVER Testing and Inspection Center Mounted Brake Lamp: Testing and Inspection INSPECT HI-MOUNTED STOP LIGHT ASSEMBLY CONTINUITY Using the ohmmeter, check that continuity exists between terminal 1 and terminal 2. If continuity is not as specified, replace the light assembly or bulb. Page 5331 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. - At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install them to the switch. INSTALLATION Installation is in the reverse order of removal. Page 6187 Cruise Control: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 3730 Steps 1 - 2 Page 5968 Page 2629 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Testing and Inspection Fuel Gauge: Testing and Inspection INSPECT FUEL RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. c. Connect terminals 1 and 3 on the wire harness side connector through a 3.4 watts test bulb. d. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves towards the full side. HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. INSPECT FUEL RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. w/ Tachometer Page 4096 A. Disconnect shock absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the 8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint. Page 3072 Page 886 Spark Plug: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT SPARK PLUGS a. Remove the ignition coils (with igniter). b. Using a 16 mm plug wrench, remove the spark plugs. c. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. Recommended Spark Plug Page 4689 Glossary Of Terms And Symbols (Part 2) Locations Fuse Block: Locations Driver Side J/B And Integration Relay Page 5652 Supplemental Restraint System Page 4295 B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. NOTE: Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of brake vibration on this vehicle. G. Determine if TSB BROO4-02 has already been performed. Repair Procedure No. 1 1. Remove the front wheel. 2. 2WD: Using a screwdriver and hammer remove the grease cap. 3. 4WD: Disconnect drive shaft. A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. Page 2463 Page 2114 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Air conditioning switched OFF 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Diagram Information and Instructions Relay Box: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 4699 Driver Side J/B And Integration Relay Page 5006 Page 6325 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 5287 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. Page 3268 Steps 1 - 2 Page 1118 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2745 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SRS AIRBAG PRECAUTION CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front passenger airbag and failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a 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 described. 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. 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.) Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one. Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the SRS is completed, check the SRS warning light check. 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 systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. If the vehicle is equipped with a mobile communication system, refer to the precaution. Page 4344 Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 4322 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: Page 6982 Windshield Page 6228 2. ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK-OUT-BOX AND TOYOTA HAND-HELD TESTER a. Connect the TOYOTA break-out-box and TOYOTA hand-held tester to the vehicle. b. Read the ECM input/output values by following the prompts on the tester screen. c. Please refer to the TOYOTA hand-held tester which has a "Snapshot" function. This records the measured data and is effective in the diagnosis of intermittent problems. 3. MONITOR ECM DATA BY USING TOYOTA HAND-HELD TESTER a. Connect the TOYOTA hand-held tester to the DLC3. b. Monitor the ECM data by following the prompts on the tester screen. HINT: TOYOTA hand-held tester has a "Snapshot" function which records the monitored data. Please refer to the TOYOTA hand-held tester operator's manual for further details. Diagnostic Trouble Code Descriptions For information regarding B, C, P, U and Manufacturer Code Descriptions - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For information regarding diagnosis of all B, C, P, U and Manufacturer Codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Page 4614 Engine Compartment Instrument Panel Locations Page 5604 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3438 Step 3 Page 5105 - Length: 6 in. ^ Ratcheting tie down strap (quantity 1) - Minimum Width & Length: 1 in. x 6 ft. ^ Bicycle Cable Lock (quantity 1) - Minimum Width & Length: 3/8 in. x 5 ft. - Built-in lock with key - Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent IV. Background On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame cross-member. In the worst case the spare tire stowed under the truck bed may become separated from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or associated brake lines. Page 6211 Cruise Control: Electrical Diagrams Service Hints C19 CRUISE CONTROL ECU 12 - GROUND: 4 pulse with 1 rotation of the rotor shaft 2 - GROUND : Approx. 12 volts with brake pedal depressed 9 - GROUND : Approx. 12 volts with ignition SW at ON position 16 - GROUND: Always continuity C16 CRUISE CONTROL SW [COMB. SW] 5 - 3 : Approx. 1540 ohms with CANCEL SW on Approx. 240 ohms with RES/ACC SW on Approx. 630 ohms with SET/COAST SW on Page 2509 Oxygen Sensor: Mechanical Specifications Torque: Sensor 1 ................................................................................................................................. ............................................... 44 N.m (450 kgf.cm, 32 ft.lbf) Sensor 2 .............................................................................................................................................. .................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Page 5403 2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. - If there is slack in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free through the shock from the airbag deploying. - Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. Page 4510 Parking and Paint Protection ^ Storage areas should be paved, well lit and secure. If your off-site storage lot is not paved, spread gravel down to minimize mud and dust. Be sure vehicles are driven carefully when moving them to or from a long-term lot. This will help minimize damage to the paint finish from road grit or gravel. ^ Park vehicles from right to left at least three feet apart. Leave enough space front and rear to easily walk between rows. ^ HVAC vent controls should be set to "Recirc" to minimize dust and odor intrusion. ^ Make sure the plastic door edge protectors are in place and fold in the side view mirror (if applicable). ^ Anti-rust covers or anti-rust film should remain on vehicle during storage 1. Anti-Rust Covers (behind wheel) should be removed at PDS. 2. Anti-Rust Film (applied to wheel) should be removed just prior to customer delivery. ^ Wash vehicles frequently. Battery ^ Turn off all electrical accessories, make sure windows and sunroof are closed and check that the transmission is in "park" (first or reverse for manual transmission vehicles). Do not apply the parking brake. ^ Test batteries monthly (more often in high heat or cold areas), using the Digital Battery System ^ Analyzer (P/N 00002-V8150-KIT). Refer to TSB PG001-06, "Battery Maintenance for In Stock Vehicles and Pre-Delivery" for complete battery maintenance procedures. ^ To reduce battery drain during long-term storage, remove the battery ground (-) cable of each vehicle and reinstall just before delivery to the customer. Locate the current PDS TSB on TIS for complete details. ^ If a hybrid vehicle is put into storage, the state of charge (SOC) of it's battery and auxiliary battery will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage, proper maintenance is necessary. Refer to TSB "Maintenance for HV & Auxiliary Batteries" for procedure and additional information. Tire Inflation Pressure If the vehicle is parked for long periods without being moved, a flat spot may develop on each tire surface in contact with the ground, even if the tires are inflated to specification. Tire inflation pressure should be checked once a month. Tire inflation pressure for storage only: 45 psi. Parts Rust If the vehicles in your storage area are exposed to a sea breeze and/or a significant precipitation corrosion with rust in some parts may occur. If rust is found remove it and treat it by applying rust inhibitor to prevent recurrence. Engine Starting and Vehicle Movement If the vehicle is stored over an extended period of time starting and running the engine periodically will ensure smooth running operation. 1. Start and operate the engine at an engine speed under 1,500 RPM for 15 minutes or longer. This also eliminates moisture in the exhaust system. NOTE Be sure to allow sufficient clearance at the rear of the vehicle to prevent other vehicles stored behind from getting damaged by exhaust gas. 2. Move the vehicle at least 30 feet to lubricate the transmission and differential and prevent tire flat-spot damage. 3. Raise engine speed above 3,000 RPM 10 times to eliminate moisture from the exhaust. A/C Compressor Lubrication To minimize the possibility of damage to the A/C compressor while storing a vehicle perform the following recommended maintenance procedures at Page 5719 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 2531 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 2184 Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT 11. REINSTALL THROTTLE BODY COVER Page 1474 4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe. 5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. 6. Check if there is any fuel leakage. h. Observe these precautions when handling nylon tube. 1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by bending it. i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 4765 Engine Room R/B Details Page 4025 (b) In this position. check the rear brake pressure If the measured value is not within the standard, replace the valve body. Page 5223 d. Remove the shims from the pressure palate. 2. REMOVE ROTOR a. Using SST, remove the snap ring. SST 95994-10020 NOTE: The snap ring should be installed so that beveled side faces up. b. Using a plastic hammer, tap the rotor off the shaft. NOTE: Be careful not to damage the pulley when tapping on the rotor. 3. REMOVE STATOR Page 4101 21. 4WD: Using the following SSTs and a press, install the bearing spacer. SST P/N: 09950-60010 (09951-00650) SST P/N: 09950-70010 (09951-07150) 22. 4WD: Install new oil seal (inside). A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). SST P/N: 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. Install steering knuckle. A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. Connect the lower ball joint to the steering knuckle with 4 bolts. Locations Supplemental Restraint System Page 2289 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 6280 Driver Side J/B And Integration Relay Page 4644 Driver Side J/B And Integration Relay Inner Circuit Page 898 Exhaust: N = T + (A - 0.30 mm (0.012 inch)) 3. Select a new shim with thickness as close as possible to the calculated value. HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787 inch) to 2.80 mm (0.1102 inch). e. Place a new adjusting shim on the valve. f. Place the valve lifter. Page 4598 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2208 Glossary Of Terms And Symbols (Part 1) Page 1851 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 8. REINSTALL INTAKE AIR CONNECTOR 9. REFILL WITH ENGINE COOLANT 10. REINSTALL THROTTLE BODY COVER Page 3200 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 2230 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 5546 Front Seat Belt Extender Applications Page 2733 A/F and 02 Sensor Identification Page 393 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 1792 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 6900 Brake Light Switch: Pinout Values and Diagnostic Parameters ABS A6, A7 ABS SPEED SENSOR FRONT LH, RH 1 - 2 : 1.40 - 1.80 kOhms (20°C, 68°F) A19 ABS SPEED SENSOR REAR 1 - 2 : 0.89 - 1.29 kOhms (20°C, 68°F) 3 - 4 : 0.89 - 1.29 kOhms (20°C, 68°F) A5 ABS ACTUATOR WITH ECU 6 - GROUND : 10 - 14 volts with ignition SW at ON or ST position 24 - GROUND : 10 - 14 volts with stop light SW on (Brake pedal depressed) 2, 18 - GROUND : Always continuity S4 STOP LIGHT SW 2 - 1 : Closed with brake pedal depressed Page 1992 CHART 22 Page 4812 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1082 Glossary Of Terms And Symbols (Part 1) Page 2840 Oxygen Sensor: Mechanical Specifications Torque: Sensor 1 ................................................................................................................................. ............................................... 44 N.m (450 kgf.cm, 32 ft.lbf) Sensor 2 .............................................................................................................................................. .................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Page 95 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 5343 - If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. REPLACEMENT REQUIREMENTS CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. AIRBAG HARNESS INSPECTION HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. Check 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. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Codes. AIRBAG SENSOR ASSEMBLY VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given. a. Check the heated oxygen sensors operation. b. See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 616 CHART 7 Page 476 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Page 840 Page 4511 least once a month to lubricate the compressor. 1. Turn off A/C and blower switches prior to starting engine. 2. Start and warm up the engine until engine idle drops below 1,000 rpm. 3. Turn on the A/C system (including the rear A/C) using the following settings: A. A/C Switch: On B. Blower Speed: High C. Engine Speed: Below 1,000 RPM 4. Keep A/C on with engine idling for at least one minute (in dual A/C vehicles leave on for two minutes). 5. Turn off A/C system and stop engine. Disk Brake Rotor Surface Rust Removal The brake rotors are made of cast iron so they may show gradual build-up of surface rust during long term storage. At least once every two months drive the vehicle and use the brakes normally stopping from about 30 mph at least 20 times. This regular usage will help prevent severe rust build up and the possibility of unwanted brake vibration concerns due to rust. NOTE ^ If the brake vibration still occurs after the braking cycle, determine the root cause of the brake vibration and repair. ^ Brake rotor resurfacing may be required if the rust was severe and resulted in excessive rotor thickness variation. Page 3049 Fuel Supply Line: Testing and Inspection INSPECTION INSPECT FUEL TANK AND LINE a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Page 1604 Engine Coolant Temperature (ECT) Sensor Page 507 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Page 1066 Engine Room R/B Fuse Applications (Part 2) Engine Room Fuse Details Locations Upper Side Moulding / Trim: Locations Roof Drip Side Finish Moulding Page 2885 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection 5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire harness side connector. Testing and Inspection Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Four Wheel Drive Selector Relay; Testing and Inspection; Procedures. Front Seat Cover - Damaged Seat Cover: Customer Interest Front Seat Cover - Damaged BODY BO006-02 Title: FRONT SEAT COVER DAMAGE Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats March 1, 2002 Introduction Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could potentially wear a hole into the seat cover material during entry and exit of the vehicle. This condition has been addressed and corrected in production. The instructions below will illustrate how to properly repair vehicles with this condition. Applicable Vehicles 2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN shown below. 2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN shown below. Production Change Information Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Page 4661 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2022 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 6370 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Page 4220 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. ^ 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. ^ 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Page 4876 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Page 1764 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 3174 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Page 6522 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 6985 a. Remove the 4 screws and 2 sun visors. b. w/ Light: Disconnect the connector. 5. REMOVE SUB-VISORS Remove the 4 screws and 2 sub-visors. 6. REMOVE FRONT PERSONAL LIGHT a. Using a screwdriver, remove the left side lens. HINT: Tape the screwdriver tip before use. b. Remove the 2 screws. c. Using a screwdriver, rotate the clip by 90 degrees and remove it. HINT: Tape the screwdriver tip before use. d. Remove the front personal light, then disconnect the connector. 7. REMOVE SUN VISOR HOLDERS Remove the 2 screws and 2 sun visor holders. 8. REMOVE FRONT PART OF ROOF HEADLINING 9. REMOVE WIPER ARMS a. Using a screwdriver, remove the 2 caps. HINT: Tape the screwdriver tip before use. b. Remove the 2 nuts and wiper arms. 10. REMOVE COWL LOUVER Remove the 8 screws, 6 clips and cowl louver. 11. REMOVE FRONT PART OF ROOF SIDE RAIL WEATHERSTRIP LH AND RH Pull the front part of roof side rail weatherstrip LH and RH to remove it. 12. REMOVE WINDSHIELD OUTSIDE MOULDING Page 6867 Headlamp Relay: Testing and Inspection POWER SOURCE HEATER RELAY 1 - 2 : Closed with ignition SW on and heater blower SW on HEAD RELAY 2 - 1 : Closed with light control SW at HEAD position or dimmer SW at FLASH position Closed with engine running and parking brake lever released (w/ daytime running light) I23 IGNITION SW 2 - 3 : Closed with ignition key at ACC or ON position 2 - 4 : Closed with ignition key at ON or ST position 7 - 6 : Closed with ignition key at ON or ST position DIMMER RELAY (w/ DAYTIME RUNNING LIGHT) 4 - 3 : Closed with HEAD relay on and dimmer SW at HIGH or FLASH position Specifications Headliner: Specifications Roof Headlining Service and Repair Fuel Pressure Release: Service and Repair SFI SYSTEM PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector. b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. Front Wheel Bearing: Service and Repair Front Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 741 Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG MANUAL ON-OFF SWITCH Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the passenger airbag manual on-0ff switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the front passenger airbag is disabled, OFF indicator inside the switch will light up. Page 6231 Steps 1 - 2 INSPECTION PROCEDURE Input Signal Check INPUT SIGNAL CHECK BY USING TOYOTA HAND-HELD TESTER a. Connect the TOYOTA hand-held tester to the DLC3. b. Check the control switch (CRUISE ON-OFF, CANCEL, SET/COAST, RES/ACC). ECM Terminal Values Using Toyota Break-Out-Box ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK-OUT-BOX AND TOYOTA HAND-HELD TESTER a. Connect the TOYOTA break-out-box and TOYOTA hand-held tester to the vehicle. b. Read the ECM input/output values by following the prompts on the tester screen. c. Please refer to the TOYOTA hand-held tester which has a "Snapshot" function. This records the measured data and is effective in the diagnosis of intermittent problems. Removal and Installation Steering Wheel: Service and Repair Removal and Installation Steering Wheel Pad And Spiral Cable REMOVAL 1. REMOVE STEERING WHEEL PAD 2. REMOVE STEERING WHEEL 3. REMOVE UPPER AND LOWER COLUMN COVERS 4. REMOVE SPIRAL CABLE INSTALLATION Page 6490 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Electrical - SRS And HV Wiring Repairs Wiring Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 2525 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 133 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 3599 b. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the 3 clamps with the 3 bolts. 7. FILL ATF AND CHECK FLUID LEVEL Page 573 CHART 27 Removal and Installation Power Steering Pump: Service and Repair Removal and Installation Page 3656 Page 6354 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2821 CHART 20 Page 1783 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 4663 Glossary Of Terms And Symbols (Part 1) Page 3954 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 2195 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 3280 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Testing and Inspection Power Mirror Motor: Testing and Inspection INSPECT MIRROR MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 3 and negative (-) lead to terminal 1. Check that the mirror turns to left side. b. Remove the polarity, check that the mirror turns to right side. c. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1. Check that the mirror turns upward. d. Reverse the polarity, that the mirror turns downward. If operation is not as specified, replace the mirror assembly. Page 6362 1. PROBLEM NO.1 Troubleshooting No. 2 Step 2 2. PROBLEM NO.2 Page 4378 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. ^ 09023-00100 6. REMOVE BRAKE,CALIPER AND DISC Page 5046 Diagrams Ignition Coil Specifications Firing Order: Specifications Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2 Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not as specified, replace the main sender gauge. INSPECT FUEL LEVEL WARNING SWITCH a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and check that the bulb lights up. HINT: It will take a short time for bulb to light up. b. Submerge the switch in fuel, and check that the bulb goes out. If operation is not as specified, replace the sender gauge. Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Measure the Plastigage at its widest point. Standard oil clearance: 0.027 - 0.053 mm (0.0011 - 0.0021 inch) Maximum oil clearance: 0.065 mm (0.0026 inch) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. HINT: 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 connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7". Reference Connecting rod big end inside diameter Page 5696 Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SRS AIRBAG PRECAUTION CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front passenger airbag and failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a 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 described. 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. 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.) Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one. Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the SRS is completed, check the SRS warning light check. 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 systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. If the vehicle is equipped with a mobile communication system, refer to the precaution. Page 4787 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3486 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 6828 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 5123 Stabilizer Bar: Service and Repair REMOVAL 1. DISCONNECT STABILIZER BAR LINKS Remove the 2 nuts and disconnect the stabilizer bar links from the lower suspension arms. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 2. REMOVE STABILIZER BAR a. Remove the 2 bolts, nuts and stabilizer bar with the cushions and brackets. b. Remove the 2 brackets and cushions from the stabilizer bar. Page 2672 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Electrical Specifications Alternator: Electrical Specifications Testing - Voltage/Amperage Testing - Voltage/Amperage Regulating Voltage 13.2 to 14.8 V at 77 deg F Rated - Voltage/Amperage Rated - Voltage/Amperage Rated Output 100 A at 12 V Rotor Coil Resistance 2.1 to 2.5 ohms at 68 deg F Interior - Seat Belt Extender Availability Seat Belt Extension: Technical Service Bulletins Interior - Seat Belt Extender Availability BODY BO017-02 September 30, 2002 Title: SEAT BELT EXTENDER Models: '01 - '03 Model Year Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. ^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. ^ The extender is available only in black. ^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle. Page 1720 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 5721 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 4516 Required SSTs Battery Inspection Procedure All vehicles are to be inspected according to the procedures listed below using the Digital Battery System Analyzer (P/N 00002-V8150-KIT) no more than 48 hours prior to customer vehicle delivery. In hybrid vehicles, the Digital Battery System Analyzer (SST P/N 00002-V81 50-KIT) is to be used ONLY on the AUXILIARY (12 volt) battery. 1. Connect test clamps to the battery. (If the analyzer does NOT power up automatically, press the POWER button.) 2. Select the correct USER ID (if applicable) and press the NEXT soft key. 3. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the NVS-8150 Instruction Manual. Page 3312 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Page 3002 Injector (Part 2) Page 6593 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 885 Spark Plug: Application and ID Recommended Spark Plugs DENSO K20R-U NGK BKR6EYA Page 2539 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Page 675 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 6611 Key Reminder Switch: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Page 88 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 3185 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 5567 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2107 Fuel Pressure: Testing and Inspection CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the front fuel pipe from the LH delivery pipe. d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and SST (adapter). SST 09268-45014 (09268-1190, 90405-06167) Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) e. Wipe off any splattered gasoline. f. Reconnect the negative (-) terminal cable to the battery. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a) to (e)) h. Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. i. Disconnect the TOYOTA hand-held tester from the DLC3. j. Start the engine. k. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) l. Stop the engine. m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45014 o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable to the battery. q. Check for fuel leaks. Page 1489 Spark Plug: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT SPARK PLUGS a. Remove the ignition coils (with igniter). b. Using a 16 mm plug wrench, remove the spark plugs. c. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. Recommended Spark Plug Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 3079 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection INSPECT FOG LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Engine Controls - MIL ON/DTC's P0135/P0155 Stored Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored ENGINE EG019-02 REVISED October 3, 2002 Title M.I.L. "ON" P0135 AND/OR P0155 Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia TSB REVISION NOTICE: January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in the Warranty Information table has been changed. All previous versions of this TSB should be discarded. Introduction Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been improved to correct this condition. Applicable Vehicles ^ 2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production Change Effective VINs listed below. ^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs listed below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 158 Page 2536 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 194 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 3470 Transmission Mode Indicator - A/T: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1) Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle 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 operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 4384 Using the following SSTs and a press, install the bearing spacer. ^ 09950-60010 (09951-00650) ^ 09950-70010 (09951-07150) 22. 4WD: INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). ^ 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Page 4790 Driver Side J/B And Integration Relay Page 2436 Page 2659 Mass Air Flow (MAF) Meter Page 505 Knock Sensor: Locations Knock Sensor (Part 1) Page 3762 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4336 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. ^ 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. ^ 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2997 Fuel Injector: Mechanical Specifications Injector (Part 1) Page 5371 Airbag Sensor Assembly: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the lower center cover. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor and judges whether the SRS must be activated or not. Page 5220 Compressor And Magnetic Clutch (Part 2) REMOVAL 1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES 2. STOP ENGINE 3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY 4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 5. 5VZ-FE engine REMOVE ENGINE UNDER COVER 6. 5VZ-FE engine DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both hoses. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system. 7. 2UZ-FE engine DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 nuts and disconnect the both hoses. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system. 8. REMOVE DRIVE BELT 9. 5VZ-FE engine REMOVE COMPRESSOR a. Disconnect the connector. b. Remove the 4 bolts and compressor. 10. 2UZ-FE engine REMOVE COMPRESSOR a. Disconnect the connector. b. Remove the 4 bolts and nut. c. Remove the cooler bracket. d. Remove the compressor. INSTALLATION Page 5659 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction directed by an arrow. b. Lock of the connectors is released, then disconnect the connectors. HINT: Be sure to hold both flank sides of the outer. If holding the top or bottom sides, it will obstruct disconnection. CONNECTION a. Align the male connector (on the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. c. Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.). HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. Page 6568 Seat Belt Reminder Lamp: Testing and Inspection INSPECT DRIVER'S SEAT BELT WARNING LIGHT a. Disconnect the connector B from the combination meter. b. Connect the negative (-) lead from the battery to terminal 9. c. Turn the ignition switch ON and check that the warning light lights UP. If the warning light does not light up, inspect the bulb or wire harness. INSPECT PASSENGER SEAT BELT WARNING LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. Connect the positive (+) lead from the battery to the terminal 4 and negative (-) lead terminal 16, and check that the warning light lights UP. If the warning light does not light up, inspect the bulb or wire harness Page 224 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 188 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 6799 Horn: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Keyless Entry - Remote Transmitter Programming Guide Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Programming Guide ELECTRICAL EL010-07 REVISED Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: '90 - '08 Applicable Toyota November 9, 2007 TSB REVISION NOTICE: ^ November 10, 2007: A TSB reference has been updated in the Programming column of the Application Chart. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now obsolete and should be discarded. Introduction Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. Applicable Vehicles ^ 1990 - 2008 model year applicable Toyota vehicles. Warranty Information System Identification The Application Chart contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. Should a vehicle having both VIP and Factory systems available (as identified in the Application Chart) be brought in without any remotes (or one non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has. ^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have VIR For example, the 2001 Camry XLE has Factory WRKE, but the LE and CE grades have VIR ^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. ^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. ^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so, the vehicle has a factory system. Page 2029 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 5404 d. Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700 1. Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. 2. Check functioning of the SST. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. 3. Disconnect the SST from the battery. Page 124 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 5463 Airbag Sensor Assembly: Service and Repair Removal and Installation Airbag Sensor Assembly REMOVAL NOTE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary (If the IC terminals are touched, the IC may be destroyed by static electricity.). 1. REMOVE LOWER CENTER COVER Remove the 2 clips and lower center cover. Page 6518 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Locations Page 1989 CHART 20 Page 1673 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 2926 Canister Purge Solenoid: Testing and Inspection VSV FOR EVAPORATIVE EMISSION (EVAP) INSPECTION 1. REMOVE VSV 2. INSPECT VSV a. Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30 - 34 ohms at 20 °C (68 °F) If there is no continuity, replace the VSV. b. Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. c. Inspect the VSV operation. 1. Check that air does not flow from ports. Engine - Squealing Noise On Cold Start Up Drive Belt: Customer Interest Engine - Squealing Noise On Cold Start Up ENGINE EG003-05 Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '05 Tundra & '01 - '05 Sequoia February 9, 2005 Introduction Some customers may experience abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt has been developed to correct this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. ^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Replace the accessory drive belt with the improved part. 1. Remove existing accessory drive belt. Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not as specified, replace the main sender gauge. INSPECT FUEL LEVEL WARNING SWITCH a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and check that the bulb lights up. HINT: It will take a short time for bulb to light up. b. Submerge the switch in fuel, and check that the bulb goes out. If operation is not as specified, replace the sender gauge. Page 1892 Applicable Vehicles Page 412 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Electrical Specifications Resistance Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch Specifications Compressor Clutch: Specifications Clearance 0.5 +/- 0.15 mm Fuel Pump Relay Fuel Pump Relay: Testing and Inspection Fuel Pump Relay INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP) 3. INSPECT FUEL PUMP RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 4. INSPECT FUEL PUMP RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. 5. REINSTALL FUEL PUMP RELAY 6. REINSTALL RELAY BOX COVER Page 4149 (b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the pistons when using compressed air. 3. REMOVE PISTON SEALS Using a screwdriver, remove the 4 piston seals from the cylinder. INSPECTION 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 inch) Minimum thickness: 26.0 mm (1.024 inch) Replace the disc if the thickness of the disc is at the minimum or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly. Page 6599 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5748 Accessories - Hood Protector Replacement Hood Bra: Technical Service Bulletins Accessories - Hood Protector Replacement ACCESSORIES AX004-03 August 6, 2003 Title: ACCESSORY HOOD PROTECTOR Models: '00 - '02 Tundra Introduction A new hood protector service replacement part is now available for 2000 through 2002 model year Tundra vehicles. Replace the hood protector with the revised part when required. Applicable Vehicles ^ 2000 - 2002 model year Tundra vehicles with the Toyota Genuine Accessory Hood Protector. Parts Information Repair Procedure Refer to the installation instructions provided with the hood protector kit. Warranty Information Applicable Warranty ** This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. ** Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3226 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 654 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 3519 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 5154 3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using Special Service Tool (SST), remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS speed sensor rotor (w/ABS)/spacer (w/o ABS). NOTICE: Take care not to scratch the serration of the speed sensor rotor. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY Page 1770 Page 2837 CHART 30 Page 1233 2. Tighten the union bolt by hand. 3. Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 2273 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 6708 Brake Lamp: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 3738 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 1064 Engine Compartment Instrument Panel Locations Page 2341 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Locations Sound Proofing / Insulation: Locations Page 2832 Page 1626 w/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SRS AIRBAG PRECAUTION CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front passenger airbag and failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a 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 described. 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. 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.) Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one. Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the SRS is completed, check the SRS warning light check. 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 systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. If the vehicle is equipped with a mobile communication system, refer to the precaution. Locations Relay Box: Locations Driver Side J/B And Integration Relay Page 6221 c. Output DTC using diagnosis check wire. 1. Turn the ignition switch ON. 2. Using SST connect terminals Tc and CG of DLC3. SST 09843-18020 3. Read the DTC on the CRUISE MAIN indicator light. HINT: If the DTC is not output, inspect the diagnosis circuit. As an example, the blinking patterns for codes; normal 52 are shown in the illustration. 2. ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK-OUT-BOX AND TOYOTA HAND-HELD TESTER a. Connect the TOYOTA break-out-box and TOYOTA hand-held tester to the vehicle. b. Read the ECM input/output values by following the prompts on the tester screen. c. Please refer to the TOYOTA hand-held tester which has a "Snapshot" function. This records the measured data and is effective in the diagnosis of intermittent problems. Page 697 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SRS AIRBAG PRECAUTION CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front passenger airbag and failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a 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 described. 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. 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.) Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one. Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the SRS is completed, check the SRS warning light check. 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 systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. If the vehicle is equipped with a mobile communication system, refer to the precaution. Page 401 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 4563 Starter Motor: Testing and Inspection INSPECTION 1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. 2. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. 3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACE If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. 4. INSPECT COMMUTATOR CIRCLE RUNOUT a. Place the commutator on V-blocks. b. Using a dial, indicate the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. 5. INSPECT COMMUTATOR DIAMETER Page 4366 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. Page 3307 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH CONTINUITY a. Check that there is no continuity between terminals with switch OFF (float up). b. Check that there is continuity between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 5241 5. INSPECT AIR INLET CONTROL SWITCH CONTINUITY If operation is not as specified, replace integration circuit bulb 6. INSPECT AIR INLET INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal A4 and negative (-) lead to A1. b. Push the air inlet button in and check that the air inlet indicator lights up. If operation is not as specified, replace the integration circuit. c. Connect the positive (+) lead from the battery to terminal A11 and negative (-) lead to terminal A10, then check that the indicator dimes. If operation is not as specified, replace the integration circuit. Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 6152 INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3278 Vehicle Speed Sensor NO.2 Page 3509 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 4583 - If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut. 2. Using SST tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 N.m (170 kgf.cm, 13 ft.lbf) NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator. h. Clean contact surfaces of contact plate and plunger. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. i. Reinstall magnetic switch end cover. Install the plunger, new gasket, end cover and lead clamp with the 3 bolts. Torque: 1.4 kW type : 2.5 N.m (25 kgf.cm, 22 in.lbf) 2.0 kW type : 3.6 N.m (37 kgf.cm, 32 in.lbf) Page 6263 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 6432 Key Reminder And Seat Belt Warning Page 2787 Engine Bank Identification Page 4580 a. Using SST, remove the bearing. SST 09286-46011 b. Using SST and a press, press in a new bearing. NOTE: Be careful of the bearing installation direction. SST 09820-00030 3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS a. Remove magnetic switch end cover. Remove the 3 bolts, end cover, gasket and plunger. b. Inspect contact plate for wear. Using vernier calipers, measure the contact plate for depth of wear. Page 2335 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2237 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Page 1117 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 5590 Seat Belt Reminder Lamp: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 2306 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 618 CHART 10 Page 6605 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 6758 Daytime Running Lamp Relay: Testing and Inspection Terminal Identification Connector Disconnected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Connector Connected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Connect the wire harness side connector to the relay and inspect wire harness side connector from the back side, as shown. If circuit is not as specified, try replacing the relay with a new one. Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH CONTINUITY a. Check that there is no continuity between terminals with switch OFF (float up). b. Check that there is continuity between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 2502 CHART 27 Page 5943 Page 2421 CHART 2 CHART 3 CHART 4 Page 1631 Thermostat: Service and Repair REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT Service and Repair Valve Seat: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 3388 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Page 966 Oil Filter: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Oil; Service and Repair. Page 87 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 2772 Page 4253 Brake Drum: Specifications Brake Drum Standard Inside Diameter 295.0 mm Maximum Inside Diameter 297.0 mm Page 4071 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 671 Glossary Of Terms And Symbols (Part 2) Page 4046 Required SSTs Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. Page 3317 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Page 2399 Applicable Vehicles Page 6687 Transmission Mode Indicator - A/T: Description and Operation ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR SYSTEM OUTLINE The electronically controlled transmission electrically controls the, throttle pressure, lock-up pressure, and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls the gear shift timing and lock-up timing in response to the vehicle's driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection of the gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. GEAR SHIFT OPERATION When driving, the engine warm up condition is input as a control signal from the engine coolant temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA, VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. LOCK-UP OPERATION When the engine control module decides based on each signal that the lock-up condition has been met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the electronically controlled transmission solenoid to GROUND. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input to TERMINAL STP of the engine control module. As a result, the engine control module cuts the current to the solenoid to release the lock-up. 4. OVERDRIVE CIRCUIT - O/D main SW on When the O/D main SW is switched to ON position, a signal is input to TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range, through the control of the engine control module. - O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range through the control of the engine control module. When in the overdrive range already, shift down is made. Page 6249 Audible Warning Device: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 5300 Hose/Line HVAC: Testing and Inspection REFRIGERANT LINE ON-VEHICLE INSPECTION 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Page 2760 CHART 15 Page 3765 Electronically Controlled Transmission And A/T Indicator (Part 3) Page 5106 Page 2455 Engine Controls - Error When Reprogramming ECU Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Page 2366 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Page 3752 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1371 Intake Manifold: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 4453 Parking Brake Pedal: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK PARKING BRAKE PEDAL TRAVEL Depress the parking brake pedal all the way and count the number of clicks. Parking brake pedal travel at 294 N (30 kgf, 66 lbs.): 6 - 9 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL TRAVEL HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 3. (a) Remove the scuff plate LH. (b) Remove the cowl side trim LH. (c) Remove the lower finish panel. (d) Remove the No. 2 heater to register duct. (e) Loosen the lock nut and turn the adjusting nut until the pedal travel is correct. (f) Tighten the lock nut. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) (g) Install the removed parts. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 2788 A/F and 02 Sensor Identification Page 1725 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 1173 9. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B)and (C). 10. Install the oil feed pipe and 22 bearing cap bolts as shown. HINT: Each bolt length is indicated in the illustration. Bolt length: 25 mm (0.98 inch) for A 38 mm (1.50 inch) for B 52 mm (2.05 inch) for C 72 mm (2.83 inch) for D 94 mm (3.70 inch) for E 11. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Torque: Bolt A: 7.5 Nm (80 kgf-cm, 69 inch lbs.) Others 16 Nm (160 kgf-cm, 12 ft. lbs.) 12. Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. 13. Remove the service bolt. Page 3131 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Page 4666 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 652 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 5496 CAUTION For this procedure, do not use pliers. They may damage the webbing. C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures 5&6 Page 5960 II. Identification of Affected Vehicles Page 3804 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 5044 Page 6218 a. Inspect the SET switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Push the control switch downward for the SET/COAST. 4. After releasing the switch, check that the vehicle cruises at the desired speed. b. Inspect the ACC (acceleration) switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check that the vehicle speed increases while the control switch is turned to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. 4. Momentarily push the control switch upward in the RES/ACC direction and then immediately release it. Check that the vehicle speed increases by about 1.5 km/h (Tap-up function). c. Inspect the COAST switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check that the vehicle speed decreases while the control switch is turned to SET/COAST; and the vehicle cruises at the set speed when the switch is released. 4. Momentarily push the control switch downward for the SET/COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap-down function). d. Inspect the CANCEL switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset. - Depress the brake pedal. - Shift into except D position. - Push the main switch OFF. - Pull the cruise control switch for CANCEL. Page 5653 Impact Sensor: Description and Operation FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled. Page 1791 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 5074 Page 6310 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 4099 A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. SST P/N: 09950-60020 (09951-00810) SST P/N: 09950-70010 (09951-07150) 16. Install new bearing. A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. SST P/N: 09527-17011 SST P/N: 09950-60020 (09951-00910) B. Using snap ring pliers, install a NEW snap ring. 17. Install new oil seal (outside). A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). SST P/N: 09223-15030 Page 1874 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Page 3183 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Page 116 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 2512 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the oxygen sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2 c. Reconnect the oxygen sensor connector. 2. INSPECT OPERATION OF HEATED OXYGEN SENSORS Page 3210 Steps 1 - 2 Page 1087 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1555 Heater Control Valve: Service and Repair WATER VALVE REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE HINT: At the time of installation, please refer to the following item. After connection, adjust the control cable. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the hose clip and slide the hose clip along the hose. b. Disconnect the water hoses. HINT: At the time of installation, please refer to the following item. Heater radiator pipe: Push the water hose onto the heater radiator pipe as far as second ridge on the pipe. - Water valve: Push the water hose onto the water valve pipe as far as water valve. - Install the hose clip in a position, as shown in the illustration. Page 6564 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4318 8. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. 09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. Page 4981 Steering Wheel: Service and Repair Air Bag - Deployment and Disposal Deployment When Disposing of Steering Wheel Pad Only DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air-bag 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 steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY NOTE: - When disposing of the steering wheel pad (with air-bag) only, never use the customers vehicle to deploy the airbag. - Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. a. Remove the steering wheel pad. CAUTION: When removing the steering wheel pad, 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 steering wheel pad, keep the upper surface of the pad facing upward. b. Remove the connector on the steering wheel pad rear surface. Page 2462 Applicable Vehicles Page 4956 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the lock nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. 7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING AND RACK GUIDE a. Using a hexagon wrench, remove the rack guide spring cap. b. Remove the rack guide spring and rack guide. 8. REMOVE RACK HOUSING CAP Using SST, remove the rack housing cap. SST 09816-30010 9. REMOVE SELF-SOCKING NUT Using SST to stop the control valve shaft rotating, remove the nut. SST 09616-00011 10. REMOVE DUST COVER 11. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY a. Place matchmarks on the control valve housing and rack housing. b. Remove the 2 bolts and control valve housing with control valve assembly. c. Remove the gasket from the rack housing. Page 6430 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4619 Interior Panel Fuse Details Page 1887 A/F and 02 Sensor Identification Page 3157 Step 1 Service and Repair Transmission Temperature Sensor/Switch: Service and Repair ON-VEHICLE REPAIR 1. 5VZ-FE: DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission. 2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 4. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR NOTICE: Be careful not to twist the wire harness. 6. CONNECT OIL COOLER PIPE a. Install the elbow to the transmission. Page 6072 Page 5374 Airbag Sensor Assembly: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 2207 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... .......................................................... 0.15 - 0.25 mm Exhaust ........................................................... ............................................................................................................................................... 0.25 0.35 mm Diagrams Back Window Glass Page 3611 12. INSTALL DETENT SPRING Install the detent spring and spring plate with the bolt. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) 13. MAKE SURE MANUAL VALVE MOVES SMOOTHLY Page 1701 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 4575 4. DISCONNECT THROTTLE BODY ASSEMBLY FROM INTAKE MANIFOLD 5. REMOVE INTAKE MANIFOLD ASSEMBLY 6. REMOVE STARTER a. Remove the 2 bolts holding the starter to the cylinder block. b. Disconnect the starter from the cylinder block. c. Disconnect the starter connector. d. Remove the nut, bolt and disconnect the starter wire. e. Remove the bolt, and disconnect the engine wire protector from the starter. f. Remove the starter. INSTALLATION 1. INSTALL STARTER a. Install the engine wire protector to the starter with the bolt. Torque: 9.81 N.m (100 kgf.cm, 84 in.lbf) b. Connect the starter wire with the nut. Torque: 9.81 N.m (100 kgf.cm, 84 in.lbf) c. Connect the starter connector. d. Connect the starter to the cylinder block. Page 590 Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 3175 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Page 2908 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1490 d. Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. e. Adjust the spark plug electrode gap. Electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) g. Reinstall the ignition coils (with igniter). Page 6965 a. Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. b. Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner. 2. POSITION GLASS a. Place the glass in the correct position. b. Check that all contacting parts of the glass rim are perfectly even. c. Place reference marks between the glass and body. d. Remove the glass. 3. COAT CONTACT SURFACE OF BODY WITH PRIMER "M" Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTE: Let the primer coating dry for 3 minutes or more. - Do not coat Primer M to the adhesive. - Do not keep any of the opened Primer M for later use. 4. Fixed type: COAT CONTACT SURFACE OF GLASS WITH PRIMER "G" Page 2322 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 850 Wheel turning angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-in and wheel angle within the specified value. At this time, make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less Page 1091 Fuse Block: Connector Views Engine Room R/B Page 4188 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. ^ 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. 20. 2WD: INSTALL NEW LOCK NUT A. Using the following SST, install and torque a NEW lock nut to the axle hub. ^ 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. 21. 4WD: INSTALL BEARING SPACER Page 610 Testing and Inspection Power Door Lock Switch: Testing and Inspection Master switch INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 5932 Page 2488 CHART 16 CHART 17 Page 4525 Battery: Specifications Parasitic Draw: Information not supplied by the manufacturer. Page 6337 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 4154 Brake Pad: Service and Repair REPLACEMENT 1. REMOVE FRONT WHEEL 2. INSPECT PAD LINING THICKNESS Check the pad thickness and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 inch) 3. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 4. REMOVE 2 PADS AND 4 ANTI-SQUEAL SHIMS NOTICE: The anti-rattle spring and clip can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 5. CHECK DISC THICKNESS AND RUNOUT Page 5707 Required SSTs Repair Procedure 1. Make sure the vehicle is stationary during the test. 2. Insert a compact disc (NOT the Toyota Master CD) to make sure the radio can accept and eject the disc without damaging it. 3. Check the Toyota Master CD for any unintended scratches or dirt. Wipe away dirt using a glass cleaning cloth. If the disc is damaged, order a replacement master CD. 4. Insert the Toyota Master CD and change to track number 9. 5. Play the track for one minute. A. If skips are heard, replace the CD player. B. If NO skips are heard, the CD player is working normally. Check the customer's CDs for scratches or other damage to the discs. Confirm that the customer is using a pre-recorded CD, NOT CD-Rs or CD-RWs as they may NOT have been burned properly. NOTE: ^ Tracks 1 - 8 and 11 - 14 are reference tracks. They can be used, but the conditions are less severe than track 9. Do NOT use tracks 10 and 15. ^ Track 9 (0.8 mm scratch) is much more severe than the Toyota engineering specification in order to ensure customer satisfaction. If the customer's radio passes this test, a replacement radio will NOT improve the performance. ^ This disc has been specially manufactured with a physical defect for the purposes of testing the CD player's performance. It is NOT possible to make copies of this disc that can be used to test the CD player's performance. Page 2593 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. Page 1795 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 2499 Page 5636 3. Using a screwdriver, remove the roof side rail garnish. HINT: Tape the screwdriver tip before use. f. Remove the front door rear scuff plate and cover. 1. Remove the clip cover. 2. Remove the clip and front door rear scuff plate. g. Remove the retractor of front seat outer belt. CAUTION: Never disassemble the front seat outer belt. NOTE: When removing the retractor of front seat outer belt, take care not to pull the seat belt pretensioner wire harness. 1. Disconnect the pretensioner connector as shown in the illustration. CAUTION: When removing the seat belt pretensioner, 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. 2. Remove the bolt and retractor of front seat outer belt. REPLACEMENT REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking items 1-(b) or 2-(b). - If the front seat outer belt has been dropped. CAUTION: For removal and installation of the seat belt pretensioner. Be sure to follow the correct procedure. INSTALLATION NOTE: - Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts. - Make sure that the front seat outer belt is installed with the specified torque. - If the front seat outer belt has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front seat outer belt with a new one. - When installing the front seat outer belt, take care that the wiring does not interfere with other parts and is not pinched between other parts. 1. Access cab: INSTALL FRONT SEAT OUTER BELT Diagrams Blower Unit Front Wheel Bearing: Service and Repair Front Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. Ground Locations Seat Belt Reminder Buzzer: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Testing and Inspection Power Mirror Switch: Testing and Inspection Left side INSPECT MIRROR SWITCH INSPECTION Right side INSPECT MIRROR SWITCH INSPECTION If continuity is not as specified, replace the switch. Page 1927 CHART 21 Diagrams Heater Unit Page 3530 Shifter A/T: Service and Repair Page 4549 e. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. f. Remove the generator from SST (C). g. Turn SST (B), and remove SST (A and B). h. Remove the pulley nut and pulley. 6. REMOVE RECTIFIER END FRAME a. Remove the 3 nuts. b. Using SST, remove the rectifier end frame. SST 09286-46011 c. Remove the generator washer from the rectifier end frame. 7. REMOVE ROTOR FROM DRIVE END FRAME REASSEMBLY Page 4921 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 6728 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 59 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 4805 Glossary Of Terms And Symbols (Part 1) Page 3363 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Locations Page 6479 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 1685 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Page 4282 HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2 seconds. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Loosen the lock nut. (b) Adjust the length of the shackle No. 2. Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch) Adjustment range: 112 - 128 mm (4.41 - 5.04 inch) HINT: One turn of the nut changes the fluid pressure as shown in the following specification. 7.4 kPa (0.76 kgf/cm, 11 psi) (c) Torque the lock nut. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body. Low pressure-Lower body High pressure-Raise body (e) Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be adjusted, inspect the valve body. 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with the load sensing spring or move it. Page 5777 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1306 12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding the bracket forward (refer to illustration). 13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following sequence: bolt 2, bolt 1, bolt 3. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) 14. Remove the accessory drive belt tensioner. 15. Install the NEW accessory drive belt tensioner. 16. Reassemble in the reverse order of disassembly. 17. Refill cooling system. Page 1533 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 8. REINSTALL INTAKE AIR CONNECTOR 9. REFILL WITH ENGINE COOLANT 10. REINSTALL THROTTLE BODY COVER Brakes - Front Brakes Vibrate Upon Application Technical Service Bulletin # BR004R-02 Date: 050404 Brakes - Front Brakes Vibrate Upon Application BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '05 Tundra September 12, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The following sections have been updated, expanded, or added: Introduction, Warranty Information, Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB. ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque specification in step 24, was changed. ^ September 8, 2003: A torque specification in step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improvements have been made to various brake components to help improve this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown. Production Change Information System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given. a. Check the heated oxygen sensors operation. b. See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 4746 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 3424 Fluid - A/T: Testing and Inspection FLUID INSPECTION 1. Check fluid level, as follows: NOTE: Drive the vehicle so that the engine and transaxle are at normal operating temperature. ATF temperature: 70 - 80°C (158 - 176°F). Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. a. Park the vehicle on a level surface and set the parking brake. b. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from the Park (P) to Low (L) position and return to the P position. c. Pull out the oil level gauge and wipe it clean. d. Push it back fully into the pipe. e. Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add new Automatic Transmission Fluid. Fluid type: ATF D-II or DEXRON III (DEXRON II) NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. Page 3449 Splice Location B11 Page 3041 Fuel Tank And Line Page 4913 Key Reminder Switch: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 3806 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Removal and Installation Alternator: Service and Repair Removal and Installation Generator (Part 1) Page 5904 Locations Engine Room R/B Page 4204 A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. SST P/N: 09950-60020 (09951-00810) SST P/N: 09950-70010 (09951-07150) 16. Install new bearing. A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. SST P/N: 09527-17011 SST P/N: 09950-60020 (09951-00910) B. Using snap ring pliers, install a NEW snap ring. 17. Install new oil seal (outside). A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). SST P/N: 09223-15030 Page 3820 STANDARD VALUE OF ECU TERMINAL Page 1279 12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding the bracket forward (refer to illustration). 13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following sequence: bolt 2, bolt 1, bolt 3. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) 14. Remove the accessory drive belt tensioner. 15. Install the NEW accessory drive belt tensioner. 16. Reassemble in the reverse order of disassembly. 17. Refill cooling system. Page 6710 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 6877 Glossary Of Terms And Symbols (Part 1) Page 2227 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 4144 Brake Caliper: Specifications Caliper Anchor Bolts 123 Nm Bleeder Screw 11 Nm Hydraulic Brake Line 15 Nm Keyless Entry - Remote Transmitter Programming Guide Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Programming Guide ELECTRICAL EL010-07 REVISED Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: '90 - '08 Applicable Toyota November 9, 2007 TSB REVISION NOTICE: ^ November 10, 2007: A TSB reference has been updated in the Programming column of the Application Chart. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now obsolete and should be discarded. Introduction Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. Applicable Vehicles ^ 1990 - 2008 model year applicable Toyota vehicles. Warranty Information System Identification The Application Chart contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. Should a vehicle having both VIP and Factory systems available (as identified in the Application Chart) be brought in without any remotes (or one non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has. ^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have VIR For example, the 2001 Camry XLE has Factory WRKE, but the LE and CE grades have VIR ^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. ^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. ^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so, the vehicle has a factory system. Page 4723 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4352 A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. SST P/N: 09950-60020 (09951-00810) SST P/N: 09950-70010 (09951-07150) 16. Install new bearing. A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. SST P/N: 09527-17011 SST P/N: 09950-60020 (09951-00910) B. Using snap ring pliers, install a NEW snap ring. 17. Install new oil seal (outside). A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). SST P/N: 09223-15030 Page 987 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Ethylene-Glycol Coolant Do Not use alcohol type antifreezs or plain water alone. Page 418 Key Reminder And Seat Belt Warning Specifications Valve Body Valve Body: Service and Repair Valve Body DISASSEMBLY NOTICE: Disassembling and reassembling should be conducted on a clean vinyl sheet or mat, or aluminum tray. - Make the valve slide through the valve hole by its own weight. Do not forcibly pull out the valve using needle-nose pliers. When having difficulty in removing it, slant and shake the valve body or use a magnet hand. - Do not place the disassembled parts directly on metal work bench or waste cloth. - Do not use dropped parts. - Make sure that no burr is identified before assembling. Page 4198 Required SSTs Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. Page 6545 Seat Belt Reminder Lamp: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2584 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Page 3247 Transmission Mode Indicator - A/T: Testing and Inspection ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 4, 7, 8 - GROUND : Approx. 13 Ohms O4 O/D MAIN SW 3 - 1 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S4 STOP LIGHT SW 1 - 2 : Closed with brake pedal depressed E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position S2, SL - E1 : 0 - 1.5 volts with vehicle not move STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F) OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F) VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with ignition SW on and throttle valve fully open VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off SPD - E1 : Pulse generation with vehicle moving 2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position +B - E1 : 9 - 14 volts with ignition SW at ON or ST position BATT - E1 : Always 9 - 14 volts P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever in 2 position 3 - 8 : Closed with shift lever in L position Page 2596 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Electrical Specifications Page 5104 A. AFFECTED VIN RANGE III. Preparation A. PARTS ^ No parts are required for the inspection. B. EQUIPMENT & MATERIALS ^ Protective eyewear ^ Standard heater core hose Page 5176 3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using Special Service Tool (SST), remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS speed sensor rotor (w/ABS)/spacer (w/o ABS). NOTICE: Take care not to scratch the serration of the speed sensor rotor. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY Page 2236 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 3942 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 3203 d. Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. e. Adjust the spark plug electrode gap. Electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) g. Reinstall the ignition coils (with igniter). Page 904 Part 2 of 4 Part 3 of 4 Page 6958 INSPECT PASSENGER'S DOOR POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT POWER WINDOW MASTER SWITCH CIRCUIT Disconnect the connector from the master switch and inspect the connector on the wire harness side. * Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver or a passenger's door is opened after the ignition switch is turned ON to OFF (ACC). If the circuit is not as specified, inspect the circuits connected to other parts. Page 1747 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 4827 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2444 CHART 27 Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH CONTINUITY a. Check that there is no continuity between terminals with switch OFF (float up). b. Check that there is continuity between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 6314 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5938 Locations Engine Room R/B Page 5812 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations Daytime Running Lamp Relay: Locations Instrument Panel Page 4964 a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. b. Coat the teflon rings with power steering fluid. c. Install the valve assembly into the valve housing. NOTICE: Be careful not to damage the teflon rings and oil seal. 8. INSTALL OIL SEAL a. Coat a new oil seal lip with power steering fluid. b. Using SST, press in the oil seal. SST 09612-22011 NOTICE: Make sure to install the oil seal facing in the correct direction. 9. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY a. Place a new gasket on the rack housing. b. Align the matchmarks on the control valve housing with control valve assembly and rack housing. c. Install the 2 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 10. INSTALL SELF-LOCKING NUT Using SST to stop the control valve shaft rotating, install a new nut. SST 09616-00011 Torque: 30 Nm (300 kgf-cm, 22 ft. lbs.) 11. INSTALL DUST COVER 12. INSTALL RACK HOUSING CAP a. Apply sealant to 2 or 3 threads of the rack housing cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST, install the rack housing cap. SST 09816-30010 Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.) Page 3702 Page 2106 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 4965 c. Using a punch and hammer, stake the 2 parts of the cap. 13. INSTALL RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP a. Install the rack guide and rack guide spring. b. 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 c. Temporarily install the rack guide spring cap. 14. ADJUST TOTAL PRELOAD a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the Right-Hand and Left-Hand rack ends. b. Using a hexagon wrench, install the rack guide spring cap. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) c. Using a hexagon wrench, return the rack guide spring cap 12°. d. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00011 e. Using a hexagon wrench, loosen the rack guide spring cap until the rack guide spring is not functioning. f. Using SST, torque wrench and hexagon wrench, tighten the rack guide spring cap until the preload is within specification. SST 09616-00011 Preload (turning): 1.0 - 1.45 Nm (10 - 14.5 kgf-cm, 8.7 - 12.6 inch lbs.) Page 5364 Wire Harness And Connector Page 930 1. Remove the engine under cover. 2. Drain the engine coolant. 3. Remove the intake air connector assembly. 4. Remove the radiator fan shroud. 5. Remove the drive belt, fan, fluid coupling, and fan pulley. 6. Without disconnecting the power steering fluid lines, remove the power steering pump. HINT: Suspend the power steering pump securely. 7. Remove the drive belt idler pulley. 8. Remove the right hand (RH) No. 3 timing belt cover. 9. Remove the No.2 timing belt cover. 10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting bracket. HINT: Suspend the A/C compressor securely. 11. Disconnect the A/C compressor mounting bracket. Page 3387 Page 619 CHART 11 Page 6413 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 1520 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Ethylene-Glycol Coolant Do Not use alcohol type antifreezs or plain water alone. Locations Fuse Block: Locations Driver Side J/B And Integration Relay Page 83 Engine Compartment Instrument Panel Locations Testing and Inspection Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise, check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Ground Locations Cigarette Lighter: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 844 Page 5205 Blower Motor Relay: Testing and Inspection HEATER MAIN RELAY INSPECTION 1. REMOVE HEATER MAIN RELAY FROM NO.2 RELAY BLOCK 2. INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 4750 Glossary Of Terms And Symbols (Part 2) Testing and Inspection Brake Warning Indicator: Testing and Inspection INSPECT BRAKE WARNING LIGHT a. Disconnect the connector from the brake fluid warning switch b. Release the parking brake pedal. c. Connect the terminals on the harness side of the level Warning switch connector. d. Start the engine, check that the warning light lights up. If warning light does not light up, test the bulb or wire harness. Testing and Inspection Tail Lamp Relay: Testing and Inspection w/ Daytime running light: INSPECT TAILLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Diagrams Starter Motor: Diagrams Starter (Part 1) Locations Fuse: Locations Driver Side J/B And Integration Relay Page 6830 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2647 Terminals Of ECU - Connector Pinouts (Part 2) INSPECTION 1. REMOVE ECM 2. INSPECT ECM 3. REINSTALL ECM Page 4939 Key Reminder Switch: Pinout Values and Diagnostic Parameters KEY REMINDER AND SEAT BELT WARNING B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Restraints - OCS System Initialization Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 4643 Driver Side J/B And Integration Relay Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1209 Harmonic Balancer - Crankshaft Pulley: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Timing Belt; Service and Repair. Page 353 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 8. REINSTALL INTAKE AIR CONNECTOR 9. REFILL WITH ENGINE COOLANT 10. REINSTALL THROTTLE BODY COVER ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4696 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3559 Transmission Mode Indicator - A/T: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2827 Page 3740 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 1109 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 5612 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 6478 Step 3 Page 1119 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3060 Page 6664 Transmission Mode Indicator - A/T: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2491 Page 799 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 4906 Key Reminder Switch: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Collision / Non-Collision Inspections Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 1099 Engine Compartment Instrument Panel Locations Page 843 Page 6185 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 4731 Engine Compartment Instrument Panel Locations Page 6815 Glossary Of Terms And Symbols (Part 2) Service and Repair Front Crankshaft Seal: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Oil Pump; Service and Repair. Page 1145 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 2WD: INSTALL GREASE CAP 8. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Lightly strike the SST on its circumference evenly. b. Coat MP grease to the oil seal lip. Page 5758 Trailer Connector: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 2248 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Body - Bumper Component Repair Front Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: BUMPER COMPONENT REPAIR SECTION: EXTERIOR BULLETIN # 172 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2009 While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinforcements there is no way to certify that a repaired part will function as originally intended under all future operating conditions and subsequent collisions. Original Equipment bumper components comply with Federal Motor Vehicle Safety Standards established under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is recommended to replace damaged bumper impact energy absorbers and reinforcements with genuine new original equipment replacement parts only. For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair & Refinish Training. Visit www.crrtraining.com for training information. Page 396 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 4166 Required SSTs Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3645 5. REMOVE OIL SEAL AND OIL SLINGER a. Using SST, remove the oil seal. SST 09308-10010 b. Remove the oil slinger. 6. REMOVE REAR BEARING AND BEARING SPACER a. Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 b. Remove the bearing spacer. 7. INSTALL BEARING SPACER, REAR BEARING AND OIL SLINGER a. Install a new bearing spacer and place the rear bearing and oil slinger. b. Using SST and the companion flange, install the rear bearing, then remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) 8. INSTALL OIL SEAL a. Coat a new oil seal lip with MP grease. b. Using SST and a hammer, install the oil seal. SST 09554-22010 Oil seal drive in depth: 4.5 ± 0.3 mm (0.177 ± 0.012 inch) Page 1514 b. Apply seal packing to the sealing groove of water inlet housing as shown in the illustration. Seal packing: Part No. 08826-00100 or equivalent ^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening. ^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. ^ Immediately remove nozzle from the tube and reinstall cap. c. Install a new O-ring to the water inlet housing. d. Apply soapy water on the O-ring. e. Attach the water inlet housing end to the front water bypass joint hole. f. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) HINT: Each bolt length is indicated in the illustration. Bolt length: 76 mm (3.00 inch) for A 22 mm (0.87 inch) for B g. Connect the water bypass hose to the water inlet housing. 3. INSTALL NO.2 IDLER PULLEY 4. INSTALL TIMING BELT 5. FILL WITH ENGINE COOLANT 6. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 7. RECHECK ENGINE COOLANT LEVEL Page 3686 8. REMOVE STEERING KNUCKLE a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION 1. INSTALL STEERING KNUCKLE a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTICE: Be careful not to damage the oil seal and drive shaft boot. b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm (1,100 kgf-cm, 77 ft. lbs.) 2. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER a. Install the disc, brake caliper and 2 bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) b. Install the brake line clamp to the steering knuckle with bolt. Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.) 5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.) 6. 4WD: INSTALL DRIVE SHAFT LOCK NUT a. While applying the brakes, tighten the nut. Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.) b. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 9. DEPRESS BRAKE PEDAL SEVERAL TIMES 10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL Disassembly and Reassembly Page 5266 9. REMOVE NO.4 HEATER TO REGISTER DUCT 10. REMOVE COOLING UNIT a. Disconnect the connectors. b. Remove the 3 screws, bolt and the cooling unit. INSTALLATION Installation is in the reverse order of removal. Page 1900 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Locations EFI Main Relay: Locations Engine Room R/B Page 1765 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 6222 3. MONITOR ECM DATA BY USING TOYOTA HAND-HELD TESTER a. Connect the TOYOTA hand-held tester to the DLC3. b. Monitor the ECM data by following the prompts on the tester screen. HINT: TOYOTA hand-held tester has a "Snapshot" function which records the monitored data. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 564 CHART 22 Page 4197 Parts Information Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Service and Repair Fuel Pressure Release: Service and Repair SFI SYSTEM PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector. b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. Page 5735 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5736 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1831 Mass Air Flow Meter: Service and Repair MASS AIR FLOW (MAF) METER 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. REINSTALL MAF METER Install the MAF meter with the 2 screws. 4. RECONNECT MAF METER CONNECTOR Page 1081 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Service and Repair Crankshaft Main Bearing Seal: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Testing and Inspection Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Testing and Inspection Power Window Switch: Testing and Inspection Driver's Switch Passenger's Switch : Window Unlock Passenger's Switch : Window Lock INSPECT POWER WINDOW MASTER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2803 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 1120 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Engine - Squealing Noise On Cold Start Up Drive Belt: All Technical Service Bulletins Engine - Squealing Noise On Cold Start Up ENGINE EG003-05 Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '05 Tundra & '01 - '05 Sequoia February 9, 2005 Introduction Some customers may experience abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt has been developed to correct this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. ^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Replace the accessory drive belt with the improved part. 1. Remove existing accessory drive belt. Page 2068 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Page 6555 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1111 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4698 Driver Side J/B And Integration Relay Page 1459 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 669 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 6239 Step 4 INSPECTION PROCEDURE HINT: Troubleshoot in accordance with the chart for each trouble symptom. Page 5596 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 4680 Engine Compartment Instrument Panel Locations Page 1956 A/F and 02 Sensor Identification Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 5621 Seat Belt Tensioner: Description and Operation SEAT BELT PRETENSIONER The seat belt pretensioner system is a component of the front seat outer belt. The pretensioner operates in the event of a frontal collision. The seat belt pretensioner cannot be disassembled. Page 5448 Step 4 Page 208 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 6400 - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 5124 3. REMOVE STABILIZER BAR LINKS a. Hold the stabilizer bar link, remove the nut. b. Remove the stabilizer bar link, 2 retainers and bushings from the stabilizer bar. c. Employ the same manner described to the other side. INSPECTION 1. INSPECT STABILIZER BAR LINK BALL JOINT BOOT FOR DAMAGE 2. INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTATION CONDITION a. As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn per 2 - 4 seconds and take the torque reading on the 5th turn. Turning torque: 0.05 - 2.0 Nm (0.5 - 20 kgf-cm, 0.4 - 17 inch lbs.) INSTALLATION 1. INSTALL STABILIZER BAR LINKS a. Install the 2 bushings, retainers and stabilizer bar link to the stabilizer bar. b. Hold the stabilizer bar link, install the nut. Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.) c. Employ the same manner described to the other side. 2. INSTALL STABILIZER BAR a. Install the 2 bushings with their cutout facing to the rearward to the stabilizer bar. b. Install the stabilizer bar and 2 brackets with nut and bolts. Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.) 3. CONNECT STABILIZER BAR LINKS TO LOWER SUSPENSION ARM Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the nut. Page 1094 Driver Side J/B And Integration Relay Inner Circuit Page 2678 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications New gasket and the ECT sensor. Torque: .......................................................................................... .................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf) New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ............................................... .................................................................................................................................. 18 N.m (185 kgf.cm, 13 ft.lbf) Page 5086 Page 6506 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 638 Page 3282 Install the No.1 vehicle speed sensor with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle speed Sensor NO.2 on-vehicle repair 1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 2 VEHICLE SPEED SENSOR a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle speed sensor. 3. INSTALL NO. 2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2 vehicle speed sensor with the bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR Testing and Inspection Positive Crankcase Ventilation: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT PCV VALVE a. Remove the PCV valve. b. Install a clean hose to the PCV valve. c. Inspect the PCV 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. 2. Blow air into the intake manifold side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. d. Remove the clean hose from the PCV valve. e. Reinstall the PCV valve. 3. INSPECT HOSES, CONNECTIONS AND GASKETS Visually check for cracks, leaks or damage. 4. REINSTALL THROTTLE BODY COVER Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2903 Glossary Of Terms And Symbols (Part 2) Page 2757 CHART 11 Page 4950 7. POSITION FRONT WHEEL FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 8. CENTER SPIRAL CABLE 9. INSTALL STEERING WHEEL a. Align the matchmarks on the wheel and steering column main shaft. b. Temporarily tighten the wheel set nut. c. Connect the connector. 10. BLEED POWER STEERING SYSTEM 11. CHECK STEERING WHEEL CENTER POINT 12. TORQUE STEERING WHEEL SET NUT Torque: 50 Nm (500 kgf-cm, 35 ft. lbs.) 13. INSTALL STEERING WHEEL PAD 14. CHECK FRONT WHEEL ALIGNMENT Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 4187 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 Page 2314 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Page 411 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Testing and Inspection Idle Up Control Valve: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start the engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rotations decrease when the vacuum hose of the air control valve is pinched. d. Check that the engine rotations increase when the hose is released. Page 2834 Page 1999 CHART 26 Page 2681 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Page 495 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. Wiring Diagram INSPECTION PROCEDURE Diagram Information and Instructions Transmission Mode Indicator - A/T: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2032 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5080 - Length: 6 in. ^ Ratcheting tie down strap (quantity 1) - Minimum Width & Length: 1 in. x 6 ft. ^ Bicycle Cable Lock (quantity 1) - Minimum Width & Length: 3/8 in. x 5 ft. - Built-in lock with key - Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent IV. Background On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame cross-member. In the worst case the spare tire stowed under the truck bed may become separated from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or associated brake lines. Locations Engine Room R/B Page 2533 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 5600 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3592 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 6192 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Service and Repair Parking Pawl: Service and Repair ON-VEHICLE REPAIR 1. REMOVE VALVE BODY 2. REMOVE PARKING LOCK PAWL BRACKET Remove the 3 bolts and parking lock pawl bracket. 3. REMOVE SPRING FROM PARKING LOCK PAWL SHAFT 4. REMOVE PARKING LOCK PAWL AND SHAFT 5. INSTALL PARKING LOCK PAWL AND SHAFT 6. INSTALL SPRING TO PARKING LOCK PAWL SHAFT A/C - Insufficient Cabin Cooling Heater Control Valve: All Technical Service Bulletins A/C - Insufficient Cabin Cooling HEATING & AIR CONDITIONING AC004-04 May 20, 2004 Title: POOR PERFORMANCE OF A/C SYSTEM Models: '01 - '04 Sequoia & '00 - '04 Tundra May 20, 2004 Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to correct the condition. Applicable ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change Effective VINs shown below. ^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 6237 ABS Light: Testing and Inspection CIRCUIT DESCRIPTION If the ECU detects a trouble, the ABS warning light comes on while the ABS control is prohibited and at the same time, the ECU records a DTC in memory. After removing the short pin of the DLC3, connect terminals Tc and CG of the DLC3 to make the ABS warning light blink and to output the DTC. Wiring Diagram Page 1440 3. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. a. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler pulley and No.2 idler pulley, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. c. Install the timing belt on the crankshaft timing pulley, No.1 idler pulley and No.2 idler pulley. 4. INSTALL TIMING BELT COVER SPACER a. Install the gasket to the cover spacer. b. Install the cover spacer. 5. INSTALL TIMING BELT GUIDE Install the belt guide, facing the cup side outward. 6. INSTALL NO.1TIMING BELT COVER Install the timing belt cover with the 4 bolts. 7. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the crankshaft pulley. b. Using SST and a hammer, tap in the crankshaft pulley. SST 09223-46011 8. INSTALL DRIVE BELT TENSIONER Install the belt tensioner with the bolt and 2 nuts. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) HINT: Use a bolt 106 mm (4.18 inch) in length. 9. INSTALL GENERATOR Page 5548 Owner Instructions Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. ^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a; different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the extender Page 6500 Audible Warning Device Control Module: Testing and Inspection LIGHT AUTO TURN OFF HEAD RELAY 2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position. Closed with the engine running and the parking brake lever released (w/ daytime running light) C15 LIGHT CONTROL SW [COMB. SW] 13 - 16 : Closed with light control SW at HEAD position 14 - 16 : Closed with light control SW at TAIL or HEAD position D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Continuity with the front LH door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with the ignition SW at ON position 14 - GROUND : Continuity with the front LH door open 3, 6 - GROUND : Always approx. 12 volts 8 - GROUND : Always continuity POWER WINDOW D16, D17 DOOR COURTESY SW LH, RH 1 - GROUND : Continuity with door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with ignition SW at ON position 3 - GROUND : Always approx. 12 volts 14 - GROUND : Continuity with front LH door open (Standard cab) 14 - GROUND : Continuity with each LH door open (Access cab) 15 - GROUND : Continuity with front RH door open (Standard cab) 15 - GROUND : Continuity with each RH door open (Access cab) P9 POWER WINDOW CONTROL SW RH 4 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is turned off, but if a door is open in the 45 seconds period, voltage will drop to 0 volts P10 POWER WINDOW MASTER SW 1 - GROUND : Always continuity 9 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is turned off, but if a door is opened in this 41.5 - 44.5 seconds period, voltage will drop to 0 volts 3 - GROUND : Approx. 12 volts with ignition SW at ON position and master SW at UP position 4 GROUND : Approx. 12 volts with ignition SW at ON position and master SW at DOWN or AUTO DOWN position WINDOW LOCK SW Open with window lock SW at LOCK position DOOR LOCK CONTROL INTEGRATION RELAY 8 - GROUND : Always continuity 3 - GROUND : Always approx. 12 volts Page 5111 Page 1973 Page 5052 FOR SPECIAL SERVICE CAMPAIGN REAR FRAME CROSS MEMBER & LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION 2000-2003 MODEL YEAR TUNDRA Lower Control Arm: Service and Repair Lower REMOVAL 1. REMOVE RH AND LH FRONT WHEELS Locations Engine Room R/B Page 1726 Page 4792 Driver Side J/B And Integration Relay Inner Circuit Page 3369 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 665 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 5539 Warranty Information Procedure 1. Owner requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet. 3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places a Critical Order for the part through the TDN Parts Network or Dealer Daily. 4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet. 6. Dealer places copy of the completed Worksheet in the customer's records. Sample Seat Belt Extender Customer Information Label Page 5797 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Locations EFI Main Relay: Locations Engine Room R/B A/T - Fluid Requirements Fluid - CVT: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information Page 4534 Alternator: Mechanical Specifications STD Minimum Slip Ring Diameter 14.2 to 14.4 mm 12.8 mm Brush Exposed Length 10.5 mm 1.5 mm Page 903 Timing Belt: Diagrams TIMING BELT REPLACEMENT W/ RELATED COMPONENTS Part 1 of 4 Page 5510 Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with a clip or tape. 2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal pliers. NOTE Be careful not to damage the webbing, since this may compromise the safety of this seatbelt. CAUTION Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MUST be replaced if: ^ The webbing is cut, frayed, worn, or damaged. ^ It has been used during a severe impact (inspect the label to ensure no impact damage has occurred) Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 7017 Windshield Washer Spray Nozzle: Adjustments FRONT WIPER AND WASHER ADJUSTMENT ADJUST WASHER NOZZLE Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield. Page 60 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 3884 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Component Locations Ignition Switch And Key Unlock Warning Switch Page 6213 Cruise Control (Part 2) Page 5569 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 310 INSPECT POWER SEAT SWITCH CIRCUIT a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. b. Inspect the connector on the wire harness side. If circuit is not as specified, inspect the circuits connected to other parts. INSPECT LUMBAR SUPPORT SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT LUMBAR SUPPORT SWITCH CIRCUIT a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. Page 4807 Relay Box: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2036 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 1709 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 3518 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 6991 c. Correct insufficient or protruded adhesive agent using a spatula. HINT: Apply the adhesive agent up to the windshield glass edge. d. Install a new windshield outside upper moulding to the windshield glass before the adhesive agent hardens. e. Using a scraper, remove any excessive adhesive agent before it hardens. f. Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardened. NOTE: Take care not to drive the vehicle during the time described in the table. 11. INSPECT FOR LEAKAGE AND REPAIR NOTE: Conduct a leak test after the hardening time has elapsed. 12. INSTALL WINDSHIELD OUTSIDE MOULDING a. Install the 4 screws and windshield outside moulding. b. Employ the same manner described above to the other side. 13. INSTALL FRONT PART OF ROOF SIDE RAIL WEATHERSTRIP LH AND RH Install the front part of roof side rail weatherstrip LH and RH. 14. INSTALL COWL LOUVER Diagram Information and Instructions Relay Box: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 4938 d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the buzzer stops sounding. If operation is not as specified, replace the combination meter. 4. INSPECT COMBINATION METER CIRCUIT Page 6445 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system/components or in the powertrain control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the DTCs remain recorded in the ECM memory. Page 3803 Vehicle Speed Sensor NO.2 Testing and Inspection Receiver Dryer: Testing and Inspection RECEIVER ON-VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints. Page 4427 1. INSTALL LSP & BV ASSEMBLY TO FRAME Install the LSP & BV assembly and 2 valve bracket mounting bolts. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) 2. CONNECT BRAKE LINE Using SST, connect the 3 brake lines. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) SST 09751-36011 3. CONNECT SHACKLE NO. 2 BRACKET (a) Set dimension A and torque the lock nut. Initial set: 120 mm (4.72 inch) Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (b) Install the shackle bracket and 2 bolts. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) (c) Connect the 2 bushings, collar and shackle No. 2 to the shackle bracket. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (d) Install the cushion retainer and nut. 4. SET REAR AXLE LOAD 5. SET VALVE BODY (a) When pulling down the load sensing spring, check that the valve piston moves down smoothly. (b) Position the valve body so that the valve piston lightly contacts with the load sensing spring. (c) Tighten the 2 valve body mounting nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With filter .............................................................................................................................................. .......................................................... 6.4 Qts.(6.1L) Without filter ....................................................... ............................................................................................................................................ 6.0 Qts.(5.7L) Service and Repair Output Shaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transfer Case; Service and Repair. Page 6887 Light Auto Turn Off Page 3224 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 5222 Compressor Clutch: Service and Repair Disassembly and Reassembly COMPRESSOR AND MAGNETIC CLUTCH DISASSEMBLY 1. REMOVE PRESSURE PLATE a. Using SST and a socket wrench, remove the shaft bolt. SST 07112-76060 Torque: 13.2 N.m (135 kgf.cm, 9 ft.lbf) b. Install SST on the pressure palate. SST 07112-66040 c. Using SST and socket wrench, remove the pressure plate. SST 07112-66040, 07112-76060, Page 6307 Cigarette Lighter: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 5239 1. INSPECT ILLUMINATION OPERATION Connect the positive (+) lead from the battery to terminal B7 and negative (-) lead to terminal AB then check that the illuminations lights up. If operation is not as specified, check the faulty bulb. 2. INSPECT BULB Apply the tester as shown in the illustration to the test for continuity. If continuity exists, replace the heater control. If no continuity exists, replace the bulb. Page 6254 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Engine - Accessory Drive Belt Squealing Noise Drive Belt Tensioner: Customer Interest Engine - Accessory Drive Belt Squealing Noise ENGINE EG026-06 REVISED Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '06 Tundra April 21, 2006 TSB REVISION NOTICE: ^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered. Previous versions of this TSB should be discarded. Introduction Some customers may experience an abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor bracket, and revised installation procedure have been developed to address this condition. Applicable Vehicles ^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Parts Information Warranty Information Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Page 4155 6. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads. (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the pistons with a monkey wrench handle or equivalent. HINT: Tape the monkey wrench handle before use. - Always change the pad on one wheel at a time as there is a possibility of the opposite piston flying out. - If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the anti-squeal shims to new pads. HINT: Apply disc brake grease to both sides of inner anti-squeal shims. (d) Install new pads. NOTICE: Do not allow oil or grease to get on the rubbing face. 7. INSTALL ANTI-RATTLE SPRING AND 2 PINS 8. INSTALL CLIP 9. INSTALL FRONT WHEEL Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) 10. DEPRESS BRAKE PEDAL SEVERAL TIMES 11. CHECK THAT FLUID LEVEL IS AT MAX LINE Page 4627 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Diagram Information and Instructions Transmission Mode Indicator - A/T: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 4402 Brake Fluid: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. Specifications Three-Way Catalytic Converter (TWC) System Page 4303 Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. Install shock absorber with coil spring. A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts. A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper, and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. Install new brake line. Using the SST, connect NEW brake line. SST P/N: 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. With ABS: Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: Install drive shaft lock nut. A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: Install grease cap. 31. Install front wheel. NOTE: Do NOT use an air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) Page 6563 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4929 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 6872 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 5660 Impact Sensor: Service and Repair Removal and Installation Front Airbag Sensor REMOVAL NOTE: - If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded. - Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. - Never reuse the sensor involved in a collision when the SRS has deployed. - Never repair a sensor in order to reuse it. Page 6876 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3339 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 5606 Glossary Of Terms And Symbols (Part 2) Page 3322 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 2033 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 493 Crankshaft Position Sensor Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Page 1572 w/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 6342 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 5031 2. CONNECT LOWER BALL JOINT TO LOWER SUSPENSION ARM Connect the lower ball joint and install the nut and a new cotter pin. Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) If the holes for the cotter pin are not aligned, tighten thee nut further up to 60°. 3. CONNECT SHOCK ABSORBER TO LOWER SUSPENSION ARM Torque: 135 Nm (1,400 kgf-cm, 100 ft. lbs.) 4. CONNECT STABILIZER BAR LINK TO LOWER SUSPENSION ARM Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 5. INSTALL POWER STEERING GEAR Torque: A bolt: 165 Nm (1,700 kgf-cm, 122 ft. lbs.) B bolt: 130 Nm (1,350 kgf-cm, 96 ft. lbs.) Bolt and nut: 265 Nm (1,700 kgf-cm, 122 ft. lbs.) 6. CONNECT RH AND LH TIE ROD ENDS Connect the RH and LH tie rod ends to the lower ball joints with the nuts and new cotter pins. Torque: 91 Nm (930 kgf-cm, 67 ft. lbs.) If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 7. INSTALL RH AND LH FRONT WHEELS Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 8. CHECK FRONT WHEEL ALIGNMENT Page 4553 b. Place the voltage regulator and brush holder on the rectifier end frame. NOTE: Be careful of the brush holder installation direction. c. Install the 5 screws. Torque: 1.96 N.m (20 kgf.cm, 17 in.lbf) d. Place the brush holder cover on the brush holder. 7. INSTALL REAR END COVER a. Install the end cover and plate terminal with the bolt and 3 nuts. Torque: Bolt: 3.85 N.m (39 kgf.cm, 34 in.lbf) Nut: 4.4 N.m (46 kgf.cm, 39 in.lbf) Page 1723 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 891 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Page 2953 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 2707 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Component Locations Wire Harness And Connector Page 2407 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Page 5697 Application Chart Page 988 Coolant: Testing and Inspection INSPECTION HINT: Check the coolant level when the engine is cold. 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the "LOW" and "FULL" lines at normal temperature (20°C (68°F)). If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the "FULL" line. 2. CHECK ENGINE COOLANT QUALITY a. Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. There should not be any excessive deposits of rust or scale around the radiator cap or radiator hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. c. Reinstall the radiator cap. Page 2716 Required Tools & Material NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Repair Procedure Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and follow the diagnostic procedure for the specific DTC. Page 6528 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 4364 ^ 09023-00100 6. REMOVE BRAKE CALIPER AND DISC A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. Page 3911 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 794 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Page 4545 1. REMOVE GENERATOR DRIVE BELT Loosen the belt tension by turning the belt tensioner counter-clockwise, and remove the drive belt. HINT: The pulley bolt for the belt tensioner has a left-hand thread. 2. REMOVE PS VANE PUMP FROM ENGINE 3. REMOVE ENGINE UNDER COVER 4. REMOVE NO.2 FAN SHROUD Remove the 2 clips and No.2 fan shroud. 5. REMOVE GENERATOR a. Disconnect the generator connector. b. Remove the cap and nut, and disconnect the generator wire. c. Disconnect the generator wire clamp from the cord clip on the generator. d. Remove the bolt, nut and generator. INSTALLATION 1. INSTALL GENERATOR a. Install the generator with the bolt and nut. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) b. Connect the generator connector. c. Connect the generator wire with the nut and rubber. d. Install the cap. e. Install the generator wire clamp to the cord clip on the generator. Page 3336 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 72 Lamp Control Module: Electrical Diagrams Service Hints LIGHT AUTO TURN OFF HEAD RELAY 2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position. Closed with the engine running and the parking brake lever released (w/ daytime running light) C15 LIGHT CONTROL SW [COMB. SW] 13 - 16 : Closed with light control SW at HEAD position 14 - 16 : Closed with light control SW at TAIL or HEAD position D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Continuity with the front LH door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with the ignition SW at ON position 14 - GROUND : Continuity with the front LH door open 3, 6 - GROUND : Always approx. 12 volts 8 - GROUND : Always continuity ILLUMINATION C15 LIGHT CONTROL SW [COMB. SW] 14 - 16 : Closed with light control SW at TAIL or HEAD position Electrical Specifications Page 6306 Splice Location B11 Page 5069 Page 5012 Ball Joint: Specifications Upper Ball Joint Turning Torque 0.7-4.4 Nm (6.0-39.0 in.lb) Page 3386 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Locations Relay Box: Locations Driver Side J/B And Integration Relay Page 1907 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 2171 Camshaft Position Sensor Page 3189 Knock Sensor: Locations Knock Sensor (Part 1) Page 5713 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 3195 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Page 5261 3. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector. b. Measure resistance between terminals. Standard resistance: 1,500 ohms at 25 °C (77 °F). If resistance is not as specified, replace the thermistor. Page 4544 Generator (Part 2) REMOVAL Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals with the switch ON (switch pin released). b. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 1953 Applicable Vehicles Locations Airbag Sensor Assembly: Locations Instrument Panel Page 3905 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 812 5. INSPECT ACTUATOR OPERATION a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD -> 4HI position. b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 2WD position. Page 2981 Fuel: Specifications Fuel Type Unleaded Gasoline Octane Rating 87 or Higher Page 5518 Seat Belt Page 3081 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Page 2437 CHART 23 Page 3688 3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using Special Service Tool (SST), remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS speed sensor rotor (w/ABS)/spacer (w/o ABS). NOTICE: Take care not to scratch the serration of the speed sensor rotor. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY Page 6515 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 4687 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 5416 Supplemental Restraint System Page 1142 DISASSEMBLY 1. 2WD: REMOVE GREASE CAP a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 2. 4WD: REMOVE OIL SEAL (INSIDE) a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). Page 2292 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 3088 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Page 1674 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Testing and Inspection Seat Sensor/Switch: Testing and Inspection Passenger's seat only: INSPECT SEAT BELT WARNING OCCUPANT DETECTION SENSOR CONTINUITY Check that continuity exists between the terminals 1 and 2 when pressing the sensing part. If operation is not as specified, replace the sensor. Page 150 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Page 4085 Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. ^ 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 2589 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 5549 and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle-release button on the extender not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. Page 1702 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 562 Page 6969 d. Hold the back window glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTE: Take care not to drive the vehicle during the time described in the table. 9. INSPECT FOR LEAK AND REPAIR NOTE: Conduct a leak test after the hardening time has elapsed. Part No. 08833-00030 or equivalent 10. INSTALL REAR PART OF ROOF HEADLINING a. Standard cab: Install the rear part of roof headlining with the 2 clips. b. Access cab: Install the rear part of roof headlining with the 3 clips. 11. INSTALL QUARTER TRIMS 12. Standard cab: INSTALL BACK PANEL UPPER GARNISH 13. Standard cab: INSTALL COAT HOOK 14. INSTALL ROOM LIGHT 15. Access cab: INSTALL ROOF SIDE RAIL GARNISHES 16. Standard cab: INSTALL FRONT PILLAR GARNISHES 17. INSTALL ASSIST GRIPS 18. Access cab: INSTALL ACCESS DOOR SCUFF PLATES 19. Standard cab: INSTALL FRONT DOOR SCUFF PLATES 20. Access cab: INSTALL REAR SEAT Page 2601 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 2510 Heated Oxygen Sensor Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 2756 CHART 10 Page 1856 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Page 3953 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Testing and Inspection Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Four Wheel Drive Selector Relay; Testing and Inspection; Procedures. Page 5911 A. AFFECTED VIN RANGE III. Preparation A. PARTS ^ No parts are required for the inspection. B. EQUIPMENT & MATERIALS ^ Protective eyewear ^ Standard heater core hose Page 5759 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 3338 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Electrical Specifications Page 6186 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 6597 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 1088 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5317 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL 1. REMOVE FRONT WHEEL Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT SPEED SENSOR CONNECTOR 3. REMOVE SPEED SENSOR (a) Remove the clips and 3 clamp bolts holding the sensor harness from the frame, upper arm and steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) (b) Remove the bolt and speed sensor from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check speed sensor signal. Page 4029 Testing and Inspection Power Door Lock Switch: Testing and Inspection Master switch INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 5020 2. REMOVE UPPER BALL JOINT a. Remove the wire and boot. b. Using a snap ring expander, remove the snap ring. c. Using Special Service Tool (SST) and a deep socket wrench, remove the upper ball joint. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) INSPECTION 1. INSPECT UPPER BALL JOINT BOOT FOR DAMAGE 2. INSPECT UPPER BALL JOINT FOR ROTATION CONDITION a. As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn per 2 - 4 seconds and take the torque reading on the 5th turn. Turning torque: 0.7 - 4.4 Nm (7 - 45 kgf-cm, 6 - 39 inch lbs.) INSTALLATION 1. INSTALL UPPER BALL JOINT a. Using Special Service Tool (SST) and a socket wrench, install a new ball joint. SST 09309-37010 b. Using a snap ring expander, install a new snap ring. c. Install a new boot and fix it with a new wire. HINT: Use the grease supplied in the kit. 2. INSTALL STEERING KNUCKLE WITH AXLE HUB Page 2445 Page 3818 c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 4LO position. d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO -> 4HI position. HINT: When inspecting the operation described, use a heater main relay. NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing. Page 6437 d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the buzzer stops sounding. If operation is not as specified, replace the combination meter. 4. INSPECT COMBINATION METER CIRCUIT Page 6101 b. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. c. Disconnect the leads from the terminals. d. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the seat back begins to fall backward. If operation is not as specified, replace the seat adjuster. INSPECT LUMBAR SUPPORT MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the lumbar support moves to release side. b. Reverse the polarity, check that the lumbar support moves forward. If operation is not as specified, replace the lumber support adjuster. INSPECT LUMBAR SUPPORT MOTOR CIRCUIT BREAKER OPERATION a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1 on the lumbar support motor connector and Page 2337 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2535 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Service and Repair Fuel Pressure Release: Service and Repair SFI SYSTEM PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector. b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. Page 3012 39 N.m (400 kgf.cm, 29 ft.lbf) for union bolts 7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt i. Install the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) j. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings. k. Position injector connector outward. l. Tighten the 4 nuts holding the delivery pipes to the lower intake manifold. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) m. Connect the 8 injectors connectors. 2. INSTALL ENGINE WIRES a. Install the 2 wire clamps on the engine wire to the brackets on the RH delivery pipe. b. Connect the engine wire clamps to the No.1 engine hanger and engine wire bracket. c. Install the engine wire protector with the 2 bolts. 3. CONNECT PCV HOSE TO PCV VALVE Page 4602 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2464 Engine Bank Identification Page 3560 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 27 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 5997 a. Using a screwdriver, remove the left side lens. b. Remove the 2 screws. c. Using a screwdriver, rotate the clip by 90 degrees and remove it. d. Remove the front personal light, then disconnect the connector. HINT: At the time of installation, please refer to the following item. When installing the front personal light, attach the clip to the housing and push it to the bracket. 12. REMOVE ROOM LIGHT a. Using a screwdriver, remove the room light cover. b. Remove the 2 screws and room light, then disconnect the connector. 13. Standard cab: REMOVE COAT HOOK a. Using a screwdriver, open the cap. b. Remove the screw and coat hook. 14. Standard cab: REMOVE BACK PANEL UPPER GARNISH Page 2484 CHART 11 Locations Engine Room R/B Page 4649 Engine Compartment Instrument Panel Locations Service Precautions Air Bag(s) Arming and Disarming: Service Precautions SRS AIRBAG PRECAUTION CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front passenger airbag and failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a 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 described. 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. 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.) Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one. Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the SRS is completed, check the SRS warning light check. 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 systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. If the vehicle is equipped with a mobile communication system, refer to the precaution. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6514 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 3324 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 2630 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 5101 Information PRELIMINARY INSPECTION INSTRUCTIONS Page 2394 A/F and 02 Sensor Identification Page 1776 Engine Control Module (ECM) Page 1936 Page 285 Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY Remove the relay box cover and starter relay. 2. INSPECT STARTER RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 3. INSPECT STARTER RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL STARTER RELAY Page 2481 CHART 7 Paint - Refinishing Bumper Cover Paint: Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Page 1830 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Page 694 Mass Air Flow (MAF) Meter Page 3491 Step 3 Page 1021 Engine Oil: Fluid Type Specifications Engine Oil Type GRADE ..................................................................................................................................... API SJ Energy-Conserving or ILSAC multigrade engine oil All temperatures ............................................ ............................................................................................................................................ 5W-30 (preferred) Above 0° F ......................................................................................................................... ....................................................................................... 10W-30 Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 5807 Trailer Connector: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Locations Anti-Lock Brake System Brakes - Vibration From Rear Brake Shoe: Customer Interest Brakes - Vibration From Rear BRAKES BR001-01 January 12, 2001 Title: REAR BRAKE VIBRATION Models: '00 - '01 Tundra TSB Update Notice: The information contained in this TSB updates BR006-00, dated November 17, 2000. Revised text is underlined. New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the star wheel adjuster has been reduced from 30 to 26 teeth. Applicable Vehicles ^ 2000 - 2001 model year Tundra vehicles. Production Change Information Parts Information Repair Procedure 1. Grind rear brake drums with brake lathe to within serviceable limits. 2. If the drums are unserviceable or above maximum inside diameter, replace the drums. 3. If there is uneven wear on the lining, replace the left and right brake shoes. 4. Replace the parking brake shoe strut sets. 5. Adjust the parking brake to specifications. 6. Reinstall the rear wheels, and torque wheel nuts to: Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf) 7. Road test. Warranty Information Brakes - Front Brakes Vibrate Upon Application Technical Service Bulletin # BR004R-02 Date: 050404 Brakes - Front Brakes Vibrate Upon Application BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '05 Tundra September 12, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The following sections have been updated, expanded, or added: Introduction, Warranty Information, Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB. ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque specification in step 24, was changed. ^ September 8, 2003: A torque specification in step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improvements have been made to various brake components to help improve this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown. Production Change Information Page 3089 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 912 Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. 18. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS a. Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise. SST 09960-10010 (09962-01000, 09963-01000) b. Disconnect the timing belt from the camshaft timing pulleys. 19. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt and timing pulley. Remove the 2 timing pulleys. SST 09960-10010 (09962-01000, 09963-01000) 20. REMOVE GENERATOR 21. REMOVE DRIVE BELT TENSIONER Remove the bolt, 2 nuts and belt tensioner. 22. REMOVE CRANKSHAFT PULLEY Using SST, remove the crankshaft pulley. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020) NOTICE: Do not turn the crankshaft pulley. 23. REMOVE NO.1 TIMING BELT COVER Remove the 4 bolts and timing belt cover. Page 202 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 2501 Page 3572 Transmission Mode Indicator - A/T: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3087 If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the ECM connector. d. Inspect the air assist system. 1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 ± 50 rpm NOTE: Perform inspection under condition without electrical load. e. After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 1 (M+) and 2 (M-). Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+). Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle control motor. d. Reconnect the throttle control motor connector. Page 4345 Parts Information Page 4117 8. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. 09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. Page 4814 Relay Box: Connector Views Engine Room R/B Lower Ball Joint: Specifications Lower Ball Joint Turning Torque 0.1-2.5 Nm (1.0-22.0 in.lb) Maximum Play 0.5 mm (0.020 in) Page 1656 Exhaust Manifold: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 4791 Driver Side J/B And Integration Relay Page 6229 Problem Symptoms Table Cruise Main Indicator Light Circuit CRUISE MAIN Indicator Light Switch CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE main indicator light lights up. Page 5629 6. Disconnect the pretensioner connector as shown in the illustration. c. Access cab: Disconnect the pretensioner connector. 1. Remove the front door scuff plate. 2. Remove the rear door scuff plate. 3. Remove the front seat outer belt floor anchor. 4. Remove the front seat outer belt shoulder belt. 5. Remove the roof side rail garnish. 6. Remove the front door rear scuff plate and cover. 7. Disconnect the pretensioner connector as shown in the illustration, d. Install the SST. 1. Buckle the front seat belt and check that there is no looseness and slack in the front seat inner belt and front seat outer belt. 2. Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082-00700,09082-00740 NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Testing and Inspection Power Seat Switch: Testing and Inspection Slide Switch Front Tilt Switch Rear Lifter Switch Reclining Switch INSPECT POWER SEAT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3543 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator, measure the torque converter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 inch) If runout is not within the specification, try to correct by reorienting the installation of the converter clutch. HINT: Mark the position of the torque converter clutch to ensure the correct installation. Page 45 Fog/Driving Lamp Relay: Testing and Inspection INSPECT FOG LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 475 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Page 4535 Generator (Part 2) Page 905 Part 4 of 4 Page 3517 Vehicle Speed Sensor NO.2 Page 1605 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3893 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 241 Windows 2000 SP2 or later Windows XP Pro SP1 or later For more information about the J2534 devices listed above, contact the vendors. To report compatibility problems with listed hardware/software, please contact the device manufacturer. For more information about Toyota vehicle reprogramming CDs or to report problems running Toyota's Calibration Update Wizard software, please contact Toyota. OBTAINING A CALIBRATION CD The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the Calibration Update Wizard application software for a Windows PC, and instructions for use. Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N 00456-REPRG-001. IMPORTANT NOTICE It is possible to permanently damage a vehicle controller during the flash reprogramming process. It is especially important to understand that once started, the reprogramming process must not be interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go into standby, hibernation or similar power management modes. The information provided herein is intended expressly for use by qualified professional automobile technicians. To prevent damage to your customer's vehicle and ensure safe service practice, read these materials completely and thoroughly before servicing the vehicle and be sure to follow all instructions. Page 2862 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5918 Page 5739 Radio/Stereo: Testing and Inspection RADIO AND PLAYER R2 (B) RADIO AND PLAYER (B) 3 - GROUND: Approx. 12 volts with ignition SW at ON or ACC position (B) 4 - GROUND: Always approx. 12 volts (B) 7 - GROUND: Always continuity S7 (D) STEREO COMPONENT AMPLIFIER (D) 3 - GROUND: Approx. 12 volts with ignition SW at ON or ACC position (D) 4 - GROUND: Always approx. 12 volts (D) 7 - GROUND: Always continuity Page 5254 2. INSTALL INTEGRATION CIRCUIT a. Connect the 2 connectors. b. Install the circuit. 3. INSTALL HEATER CONTROL HOUSING a. Connect the connector. b. Install the heater control housing. c. Install the 5 screws. 4. INSTALL BULBS Install the 5 bulbs. 5. INSTALL AIRBAG INDICATOR CIRCUIT a. Connect the connector. b. Install the circuit. Page 6283 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals with the switch ON (switch pin released). b. Check that there is no continuity between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * 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 systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 156 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 2624 Engine Control Module: Locations Instrument Panel Page 2639 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3366 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Page 5914 Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 2813 CHART 8 CHART 9 Page 3731 Step 3 Page 4761 Driver Side J/B And Integration Relay Inner Circuit Brakes - Front Brakes Vibrate Upon Application Technical Service Bulletin # BR004R-02 Date: 050404 Brakes - Front Brakes Vibrate Upon Application BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '05 Tundra September 12, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The following sections have been updated, expanded, or added: Introduction, Warranty Information, Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB. ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque specification in step 24, was changed. ^ September 8, 2003: A torque specification in step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improvements have been made to various brake components to help improve this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown. Production Change Information Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 5034 2. INSTALL NEW BUSHING Using SST, a press and steel plate, install a new bushing. SST 09631-12090, 09710-30021 (09710-03051) INSTALLATION 1. INSTALL UPPER SUSPENSION ARM Install the upper suspension arm with 2 washers, bolt and nut. Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.) HINT: After stabilizing the suspension, torque the nut. 2. INSTALL BRAKE AND FUEL LINE CLAMP Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.) 3. INSTALL REAR FENDER APRON SEAL 4. CONNECT UPPER BALL JOINT a. Connect the upper ball joint to the upper suspension arm. b. Install the nut and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm (1,100 kgf-cm, 77 ft. lbs.) 5. w/ ABS: CONNECT ABS SPEED SENSOR WIRE HARNESS CLAMPS. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 6. INSTALL SHOCK ABSORBER WITH COIL SPRING 7. CHECK FRONT WHEEL ALIGNMENT Trailer Harness - Updated Design/Diagnostics Trailer Adapter Kit: Technical Service Bulletins Trailer Harness - Updated Design/Diagnostics ACCESSORIES AX006-02 October 18, 2002 Title: TRAILER WIRE HARNESS Models: 4Runner, Highlander, land Cruiser, RAV4, Sienna, Tacoma & Tundra Introduction Beginning in 2000, the accessory trailer wire harness supplier was changed and a new design was adopted which incorporated in-line fuses in the tow wire harness in addition to the vehicle fuse. This bulletin identifies the fuse location to supplement dealer diagnostics troubleshooting. In the future please reference the accessory trailer wire harness Owner's Guide for the vehicle specific diagnostic procedures. As a general note please place the towing wire harness Owner's Guide in glove box after every DIO installation. Applicable Vehicles ^ 4Runner, Highlander, Land Cruiser, RAV4, Sienna, Tacoma, and Tundra vehicles using the Accessory Towing Receiver Hitch and factory Towing Receiver Hitch option. (See table below for applicable model years.) Accessory Wire Harness Kit Information Warranty Information Page 2701 Knock Sensor: Locations Knock Sensor (Part 1) Page 3370 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Page 2211 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 5475 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Check Steering Wheel Free Play and Effort Steering Wheel: Testing and Inspection Check Steering Wheel Free Play and Effort INSPECTION 1. CHECK STEERING WHEEL FREE PLAY a. Stop the vehicle and face the tires straight ahead. b. Rock the steering wheel gently up and down with a finger lightly, check the steering wheel free play. Maximum free play: 30 mm (1.18 inch) 2. CHECK STEERING EFFORT a. Center the steering wheel. b. Remove the steering wheel pad. c. Start the engine and run it at idle. d. Measure the steering effort in both directions. Steering effort (Reference): 4.9 Nm (50 kgf-cm, 43 inch lbs.) HINT: Take the tire type, pressure and contact surface into consideration before making your diagnosis. e. Torque the steering wheel set nut. Torque: 50 Nm (500 kgf-cm, 35 ft. lbs.) f. Install the steering wheel pad. Page 2894 Vehicle Speed Sensor NO.2 Page 5715 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 6177 Tailgate: Service and Repair REMOVAL 1. REMOVE TAILGATE PROTECTOR 2. REMOVE SERVICE HOLE COVER Using a torx socket wrench (T30), remove the 8 screws and service hole cover. 3. REMOVE TAILGATE LOCK a. Disconnect the 2 tailgate lock links from the tailgate lock control. b. Using a torx socket wrench (T40), remove the 4 screws and 2 tailgate locks. 4. REMOVE TAILGATE HANDLE ASSEMBLY Remove the 2 bolts and tailgate handle assembly. 5. REMOVE TAILGATE LOCK STRIKERS Using a torx socket wrench (T40), remove the 4 screws and tailgate lock strikers. 6. REMOVE TAILGATE CABLE a. Remove the deck side shaft and tailgate cable from deck. b. Remove the gate side shaft and tailgate cable. c. Employ the same manner described above to the other side. 7. REMOVE TAILGATE a. Remove the 2 bolts and tailgate. NOTE: Be careful not to drop the tailgate. Page 6107 b. Inspect the connector on the wire harness side. If circuit is not as specified, inspect the circuits connected to other parts. On-Vehicle Cleaning Radiator: Service and Repair On-Vehicle Cleaning ON-VEHICLE CLEANING CLEAN RADIATOR Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core.) Page 2030 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 1415 Oil Pressure Sender: Testing and Inspection INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi). If operation is not as specified, replace the switch. 5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a. Disconnect the connector from the sender gauge. b. Check that no continuity exists between the terminal and ground with the engine stopped. c. Check that continuity exists between the terminal and ground with the engine running. HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi). If the continuity is not as specified, replace the sender gauge. Page 1229 g. Reinstall the camshafts. h. Reinstall the timing belt. i. Recheck the valve clearance. 11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP COVER Page 3574 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 530 Engine Bank Identification Page 1975 Page 1331 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Testing and Inspection Brake Warning Indicator: Testing and Inspection INSPECT BRAKE WARNING LIGHT a. Disconnect the connector from the brake fluid warning switch b. Release the parking brake pedal. c. Connect the terminals on the harness side of the level Warning switch connector. d. Start the engine, check that the warning light lights up. If warning light does not light up, test the bulb or wire harness. Page 2145 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER Remove the 9 bolts, seal washers and cylinder head cover. 7. REMOVE LH CYLINDER HEAD COVER a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal washers and cylinder head cover. 8. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360°) and align the mark. 9. INSPECT VALVE CLEARANCE Page 1137 Page 681 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 1513 b. Check that the fluid coupling is not damaged and that no silicon oil leaks. If necessary, replace the fluid coupling. c. Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 5.4 Nm (55 kgf-cm, 47 inch lbs.) 3. INSPECT FAN PULLEY BRACKET Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket. 4. INSPECT TIMING BELT COMPONENTS INSTALLATION 1. INSTALL WATER PUMP a. Install a new O-ring to the water bypass pipe end. b. Apply soapy water to the O-ring. c. Connect the water pump to the water bypass pipe end. d. Install the water pump and a new gasket with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes. Torque: Bolt: 21 Nm (215 kgf-cm, 15 ft. lbs.) Stud bolt and nut: 18 Nm (185 kgf-cm, 13 ft. lbs.) 2. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and water pump. ^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. ^ Thoroughly clean all components to remove all the loose material. ^ Using a non-residue solvent, clean both sealing surfaces. Page 1582 a. Lightly tap the radiator port (inlet or outlet) with a soft-faced hammer, and remove the tank. b. Remove the O-ring. REASSEMBLY 1. INSPECT LOCK PLATE 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. Therefore, repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 2. INSTALL NEW O-RINGS AND TANKS a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. b. Install the tank without damaging the O-ring. c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank. Page 6273 Key Reminder And Seat Belt Warning Testing and Inspection Four Wheel Drive Selector Switch: Testing and Inspection INSPECTION 1. INSPECT 2WD -> 4HI SHIFT a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4 switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4 switch is in OFF position. HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be moved back and forth. - If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash. 2. INSPECT 4HI -> 4LO SHIFT Page 4119 ^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) Page 3558 Splice Location B11 Page 4873 2. REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the drive belt. 3. DISCONNECT 2 VACUUM HOSES Remove the 2 clips and disconnect the 2 vacuum hoses. 4. DISCONNECT RETURN HOSE Remove the clip and disconnect the return hose. 5. DISCONNECT PRESSURE FEED TUBE Remove the union bolt and gasket, disconnect the pressure feed tube. 6. REMOVE PS VANE PUMP ASSEMBLY Remove the 2 bolts, nut, stud bolt and PS vane pump assembly. INSTALLATION 1. INSTALL PS VANE PUMP ASSEMBLY a. Install the PS vane pump assembly with the stud bolt. Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.) b. Install the 2 bolt and nut. Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.) 2. INSTALL PRESSURE FEED TUBE a. Connect the pressure feed tube. b. Install a new gasket and the union bolt to the pressure feed tube. HINT: Make sure the stopper of the pressure feed tube touches the PS vane pump body as shown in the illustration, then torque the union bolt. Torque: 46.5 Nm (475 kgf-cm, 34 ft. lbs.) 3. CONNECT RETURN HOSE Connect the return hose with the clip. 4. CONNECT 2 VACUUM HOSES Connect the 2 vacuum hoses and install the 2 clips. 5. INSTALL DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and install the belt. 6. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 3218 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Brakes - Front Brakes Vibrating Technical Service Bulletin # BR004R-02 Date: 040305 Brakes - Front Brakes Vibrating BRAKES BR004-02 REVISED September 16, 2002 Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra TSB REVISION NOTICE: ^ March 5, 2004: A torque specification in, step 24, was changed. ^ September 8, 2003: A torque specification in, step 28, was changed. The previous TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles ^ 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 931 12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding the bracket forward (refer to illustration). 13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following sequence: bolt 2, bolt 1, bolt 3. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) 14. Remove the accessory drive belt tensioner. 15. Install the NEW accessory drive belt tensioner. 16. Reassemble in the reverse order of disassembly. 17. Refill cooling system. Page 6546 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... .......................................................... 0.15 - 0.25 mm Exhaust ........................................................... ............................................................................................................................................... 0.25 0.35 mm Page 5014 Page 4744 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2640 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2263 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 406 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Front .................................................................................................................................................... ......................................................................... 1.2 Qt Rear ................................................................ .............................................................................................................................................................. 3.7 Qt Page 2662 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Page 6275 Audible Warning Device: Testing and Inspection KEY REMINDER AND SEAT BELT WARNING B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Page 168 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Brakes - Front Brakes Vibrate Upon Application Technical Service Bulletin # BR004R-02 Date: 050404 Brakes - Front Brakes Vibrate Upon Application BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '05 Tundra September 12, 2002 TSB REVISION NOTICE: ^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The following sections have been updated, expanded, or added: Introduction, Warranty Information, Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB. ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque specification in step 24, was changed. ^ September 8, 2003: A torque specification in step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improvements have been made to various brake components to help improve this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown. Production Change Information Page 4804 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4670 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4348 4. With ABS: Disconnect ABS speed sensor and wire harness clamp from steering knuckle. Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. Disconnect brake line. Using the following SST, disconnect the brake line. Use a container to catch the brake fluid. SST P/N: 09023-00100 6. Remove brake caliper and disc. A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper, and disc. 7. Remove shock absorber. Page 4431 (b) Install the 2 collars and 4 bushings. HINT: Apply lithium soap-base glycol grease to all rubbing areas. - Do not mistake the valve side for the shackle side of the load sensing spring. 2. INSTALL SHACKLE NO. 1 AND NO. 2 Install the lock nut, plate washer and shackle No. 1 to the shackle No. 2 then install the upper nut. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) 3. INSTALL LOAD SENSING SPRING TO SHACKLE NO. 1 (a) Install the load sensing spring and 2 plate washers to shackle No. 1. (b) Install the bolt, washer and nut. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 4. INSTALL LOAD SENSING SPRING TO VALVE BODY Install the load sensing spring to the load sensing valve with the clip. 5. INSTALL VALVE BRACKET (a) Install the set plate to the load sensing valve through the valve bracket and temporarily tighten the 2 washers and 2 nuts. (b) Install the load sensing spring assembly, 2 plate washers, bolt, washer and nut. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) Page 666 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 2485 CHART 12 CHART 13 Page 1805 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Electrical Specifications Resistance Page 2363 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Testing and Inspection Interior Light Switch: Testing and Inspection INSPECT FRONT PERSONAL LIGHT SWITCH CONTINUITY a. Disconnect the connector from the personal light. b. Push the personal light switch ON, check that continuity exists between terminal 3 and body terminal 1. c. Turn the light switch to DOOR, check that continuity exists between terminal 2 and 3. If operation is as specified, replace the switch. INSPECT ROOM LIGHT SWITCH a. Disconnect the connector from the interior light assembly. b. Turn the interior light switch ON, check that continuity exists terminal 2 and body ground. c. Turn the interior light switch to DOOR, check that continuity exists between terminals 1 and 2. If operation is not as specified, replace the switch. Air Conditioning Control Assembly Control Assembly: Testing and Inspection Air Conditioning Control Assembly On-Vehicle Inspection AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration) ON-VEHICLE INSPECTION 1. REMOVE CENTER CLUSTER INTEGRATION PANEL 2. INSPECT A/C CONTROL ASSEMBLY CIRCUIT Wire Harness Side a. Disconnect the connector from the A/C control assembly and inspect the connector on the wire harness side, as shown in the chart. Test condition: Turn ignition switch to ON If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Page 5779 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2249 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 6509 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 2228 A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744). B. Test for continuity. ^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process. ^ If there is no continuity, proceed to CABLE TEST 2. CABLE TEST 2. A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744). B. Test DLC cable (P/N 02001637) for continuity. ^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3. ^ If there is no continuity, the cable needs to be replaced. CABLE TEST 3. Page 4613 Engine Room R/B Details Page 2015 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 1759 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 2618 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 4065 8. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. 09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. Page 4796 Engine Room R/B Details Page 2723 Page 4464 Vacuum Brake Booster: Service and Repair REMOVAL 1. REMOVE MASTER CYLINDER 2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3. REMOVE SCUFF PLATE LH, COWL SIDE TRIM LH, LOWER FINISH PANEL AND NO. 2 HEATER TO REGISTER DUCT 4. REMOVE PEDAL RETURN SPRING 5. REMOVE CLIP AND CLEVIS PIN 6. REMOVE BRAKE BOOSTER (a) Remove the 4 nuts and clevis. (b) Pull out the brake booster and gasket. (c) Remove the 2 stopper rings, brake booster bracket and gasket from the brake booster. INSTALLATION 1. INSTALL BRAKE BOOSTER (a) Install a new gasket to the brake booster. (b) Install the brake booster bracket and 2 stopper rings to the brake booster. (c) Install the booster and a new gasket. (d) Install the clevis to the operating rod. (e) Install and torque the booster installation nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (f) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. (g) Connect the vacuum hose to the brake booster. 2. INSTALL NO.2 HEATER TO REGISTER DUCT, LOWER FINISH PANEL, COWL SIDE TRIM LH AND SCUFF PLATE 3. ADJUST LENGTH OF BOOSTER PUSH ROD Page 2245 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 5457 Airbag Sensor Assembly: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the lower center cover. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor and judges whether the SRS must be activated or not. Page 2704 Step 1 Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Specifications Camshaft Bearing: Specifications INSTALL CAMSHAFTS 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, 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 should be carried out. a. Install the RH camshafts. 1. Apply MP grease to the thrust portion of the intake and exhaust camshafts. 2. Place the intake and exhaust camshafts. 3. Set the timing mark (1 dot mark) of the camshaft main gear at approximately 10° angle. 4. Remove any old packing (FIPG) material from front bearing cap. 5. Apply seal packing to the front bearing cap as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 1.5 mm (0.06 inch) opening. - Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. - Immediately remove nozzle from the tube and reinstall cap. NOTICE: Do not apply seal packing to the front bearing cap grooves. 6. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. 7. Install the other bearing cap in the sequence shown with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Diagram Information and Instructions Transmission Mode Indicator - A/T: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6292 Audible Warning Device Control Module: Testing and Inspection LIGHT AUTO TURN OFF HEAD RELAY 2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position. Closed with the engine running and the parking brake lever released (w/ daytime running light) C15 LIGHT CONTROL SW [COMB. SW] 13 - 16 : Closed with light control SW at HEAD position 14 - 16 : Closed with light control SW at TAIL or HEAD position D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Continuity with the front LH door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with the ignition SW at ON position 14 - GROUND : Continuity with the front LH door open 3, 6 - GROUND : Always approx. 12 volts 8 - GROUND : Always continuity POWER WINDOW D16, D17 DOOR COURTESY SW LH, RH 1 - GROUND : Continuity with door open INTEGRATION RELAY 9 - GROUND : Approx. 12 volts with ignition SW at ON position 3 - GROUND : Always approx. 12 volts 14 - GROUND : Continuity with front LH door open (Standard cab) 14 - GROUND : Continuity with each LH door open (Access cab) 15 - GROUND : Continuity with front RH door open (Standard cab) 15 - GROUND : Continuity with each RH door open (Access cab) P9 POWER WINDOW CONTROL SW RH 4 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is turned off, but if a door is open in the 45 seconds period, voltage will drop to 0 volts P10 POWER WINDOW MASTER SW 1 - GROUND : Always continuity 9 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is turned off, but if a door is opened in this 41.5 - 44.5 seconds period, voltage will drop to 0 volts 3 - GROUND : Approx. 12 volts with ignition SW at ON position and master SW at UP position 4 GROUND : Approx. 12 volts with ignition SW at ON position and master SW at DOWN or AUTO DOWN position WINDOW LOCK SW Open with window lock SW at LOCK position DOOR LOCK CONTROL INTEGRATION RELAY 8 - GROUND : Always continuity 3 - GROUND : Always approx. 12 volts Page 2353 Engine Control Module: Service and Repair VEHICLE REPROGRAMMING Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM). Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign provides direction to do so. Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool - Vetronix Mastertech - J2534 Compatible Vehicle Interface (Toyota validated and approved) REPROGRAMMING WITH SCANTOOL Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool, or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the authentic Toyota factory scantool software which runs on either of the above mentioned scantools. Scantool software version requirements are specified in applicable Technical Service Bulletin (TSB)/Service Communication (SC) documents. The Toyota/Lexus factory scantool and/or authentic factory software program cards can be purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card - P/N 01002593-005 for the "stand alone" program card Program cards are provided with the latest production version software available at time of purchase. Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system - Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software - Toyota/Lexus factory scantool program card - PC Interface Cable (P/N 01001090) to transfer data from PC to scantool - Calibration CD (00456-REPRG-001) REPROGRAMMING WITH J2534 INTERFACE Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface - Toyota Calibration Update Wizard software (available on calibration CD) - Personal Computer running Microsoft Windows 2000/XP or later operating system - Calibration CD (00456-REPRG-001) Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on this list. Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that their hardware works safely and efficiently with their products. Every device listed on this page has been thoroughly tested and validated on Toyota, Scion and Lexus vehicles. It is important to understand that only the specific devices, firmware, DLLs and APIs listed here have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware, DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's control; in some cases, changes made to device hardware/software can negatively impact reprogramming performance. Toyota makes every effort to continue to work with J2534 interface manufacturers to ensure continued product compatibility as the respective products evolve. Requirement for device: Supplier Device Name Version (Firmware* / DLL* / API*) Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04) Actia PassThru+ XS (02.01 / 02.01 / 04.04) Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04) EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04) Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04) Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04) * Original validated firmware/DLL versions may be superceded by the device manufacturer. Contact the device manufacturer if you are unable to find the versions listed above. Support OS: OS Name and Version: Front Shock Absorber With Coil Spring Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber With Coil Spring REMOVAL 1. REMOVE FRONT WHEEL Page 6610 Key Reminder And Seat Belt Warning Page 6650 w/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. A/T - Torque Converter Bolt Installation Precautions Torque Converter: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 2194 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Page 5209 11. INSTALL LOWER COVER 12. INSTALL LOWER LH FINISH PANEL 13. INSTALL LOWER CENTER COVER 14. INSTALL LOWER NO.2 FINISH PANEL 15. INSTALL GLOVE COMPARTMENT PARTS Page 4254 Brake Drum: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 92 Glossary Of Terms And Symbols (Part 2) Page 4555 a. Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTE: Be careful not to damage the fan. b. Remove the bearing cover (inside). c. Place the bearing cover (inside) on the rotor. d. Using SST and a press, press in a new bearing. SST 09820-00030 e. Using SST, push in the bearing cover (outside). SST 09285-76010 Page 521 Page 2415 Page 2785 Applicable Vehicles Locations DLC3 Engine Controls - ECU Reprogramming Procedure Technical Service Bulletin # SS002R-01 Date: 030922 Engine Controls - ECU Reprogramming Procedure SPECIAL SERVICE TOOLS SS002-01 REVISED March 9, 2001 Title: ECU FLASH REPROGRAMMING PROCESS Models: Applicable Models TSB REVISION NOTICE: ^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration files. ^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The previous TSB should be discarded. Introduction Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ or any other Toyota specific control unit Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECUs will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming. Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Warranty Information Parts Information NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Page 3668 6. REMOVE OIL SEAL (OUTER SIDE) Using SST, remove the oil seal. SST 09308-00010 7. INSPECT REAR AXLE BEARING Check for wear or damage. 8. REPLACE REAR AXLE BEARING a. Using SST and a press, remove the bearing. SST 09223-56010, 09950-60010 (09951-00560) b. Using SST and a press, install a new bearing. SST 09515-30010, 09950-60020 (09951-00890) 9. INSTALL NEW OIL SEAL (OUTER SIDE) Using SST and a hammer, install a new oil seal. SST 09950-60010 (09951-00610), 09950-70010 (09951-07150) 10. INSPECT BEARING CASE Check for wear or damage. Page 605 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 5568 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 4526 Battery: Service Precautions PRECAUTION * 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. Specifications Firing Order: Specifications Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2 Page 1981 CHART 8 CHART 9 Page 4594 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3130 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Page 3244 Electronically Controlled Transmission And A/T Indicator (Part 2) Page 6560 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4462 Page 5158 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 6305 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Front Seat Cover - Damaged Seat Bottom Frame: Customer Interest Front Seat Cover - Damaged BODY BO006-02 Title: FRONT SEAT COVER DAMAGE Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats March 1, 2002 Introduction Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could potentially wear a hole into the seat cover material during entry and exit of the vehicle. This condition has been addressed and corrected in production. The instructions below will illustrate how to properly repair vehicles with this condition. Applicable Vehicles 2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN shown below. 2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN shown below. Production Change Information Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. Page 4296 4. With ABS: Disconnect ABS speed sensor and wire harness clamp from steering knuckle. Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. Disconnect brake line. Using the following SST, disconnect the brake line. Use a container to catch the brake fluid. SST P/N: 09023-00100 6. Remove brake caliper and disc. A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper, and disc. 7. Remove shock absorber. Page 3048 Fuel Supply Line: Service Precautions FUEL TANK AND LINE PRECAUTION - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 4963 4. INSTALL BUSHING a. Coat a new O-ring with power steering fluid and install it to the bushing. b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. c. Install the bushing. NOTICE: ^ Make sure to install the bushing facing in the correct direction. ^ Be careful not to damage the oil seal lip. 5. INSTALL CYLINDER END STOPPER a. Align the installation hole for the wire of the stopper with the slot of the rack housing. b. Install a new wire into the stopper. c. Using SST, turn the stopper clockwise 450 ± 50°. SST 09631-16010 6. AIR TIGHTNESS TEST a. Install SST to the rack housing. SST 09631-12071 b. Apply 53 kPa (400 mm Hg, 15.75 inch Hg) of vacuum for about 30 seconds. c. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals. 7. INSTALL CONTROL VALVE ASSEMBLY Page 4655 Engine Compartment Instrument Panel Locations Page 6398 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Page 2702 Knock Sensor (Part 2) Page 4114 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Page 6800 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 5143 Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL. DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder, as shown in the illustration to discharge the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. REPLACEMENT REPLACE BUSHING a. Using Special Service Tool (SST), 19 mm deep socket wrench and a press, remove the bushing. SST 09632-36010 b. Using SST and a press, install a new bushing. SST 09630-24014 (09620-24041), 09632-36010 INSTALLATION 1. INSTALL REAR SHOCK ABSORBER a. Install the 2 retainers and cushion to the shock absorber. Locations EFI Main Relay: Locations Engine Room R/B Page 3194 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Page 1932 CHART 24 Page 634 Page 5264 Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. DISCONNECT LIQUID TUBE 5VZ-FE Shown a. Using SST, remove the piping clamp. SST 09870-00025 (Liquid tube) 1. Insert SST to piping clamp. HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label. 2. Push down SST and release the clamp lock. NOTE: Be careful not to deform the tubes, when pushing SST. 3. Pull SST slightly and push the release lever, then remove the piping clamp with SST. 4. Remove the piping clamp from SST. b. Disconnect the both tubes. Page 3664 Grease capacity (Color = Black): 190 - 210 g (6.70 - 7.41 oz.) b. Temporarily install the boot to the inboard joint shaft. 7. CHECK DRIVE SHAFT LENGTH a. Make sure that the 2 boots are on the shaft groove. b. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: 523.5 ± 2.0 mm (20.610 ± 0.079 inch) 8. INSTALL LARGE INBOARD JOINT BOOT CLAMP TO INBOARD JOINT SHAFT BOOT a. Place the large inboard joint boot clamp. b. Using pliers, compress the clamp and attach the claws. 9. INSTALL OTHER BOOT CLAMPS TO BOTH BOOTS a. Secure the clamp onto the boot. b. Place Special Service Tool (SST) onto the clamp. SST 09521-24010 c. Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. d. Using SST, adjust the clearance of the clamp. SST 09240-00020 Clearance: 1.0 - 1.5 mm (0.039 - 0.059 inch) 10. CHECK DRIVE SHAFT Page 2293 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 2465 A/F and 02 Sensor Identification Specifications Page 2423 CHART 7 Page 2344 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Restraints - OCS System Initialization Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 6511 Splice Location B11 Page 5098 Page 1683 4. Attach the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Techstream Preparation Selecting the TIS Techstream VIM or the Mongoose MFC VIM. Techstream software requires a VIM selection before you can use the Mongoose MFC VIM. If using TIS Techstream no changes are needed. Perform the following: 1. Select Setup from the Techstream Main Menu screen. 2. Select VIM Select from the Setup drop down menu. 3. Select the correct Interface Setup from the drop down list. ^ If using Techstream Lite select Mongoose MFC. NOTE Page 6037 Parking and Paint Protection ^ Storage areas should be paved, well lit and secure. If your off-site storage lot is not paved, spread gravel down to minimize mud and dust. Be sure vehicles are driven carefully when moving them to or from a long-term lot. This will help minimize damage to the paint finish from road grit or gravel. ^ Park vehicles from right to left at least three feet apart. Leave enough space front and rear to easily walk between rows. ^ HVAC vent controls should be set to "Recirc" to minimize dust and odor intrusion. ^ Make sure the plastic door edge protectors are in place and fold in the side view mirror (if applicable). ^ Anti-rust covers or anti-rust film should remain on vehicle during storage 1. Anti-Rust Covers (behind wheel) should be removed at PDS. 2. Anti-Rust Film (applied to wheel) should be removed just prior to customer delivery. ^ Wash vehicles frequently. Battery ^ Turn off all electrical accessories, make sure windows and sunroof are closed and check that the transmission is in "park" (first or reverse for manual transmission vehicles). Do not apply the parking brake. ^ Test batteries monthly (more often in high heat or cold areas), using the Digital Battery System ^ Analyzer (P/N 00002-V8150-KIT). Refer to TSB PG001-06, "Battery Maintenance for In Stock Vehicles and Pre-Delivery" for complete battery maintenance procedures. ^ To reduce battery drain during long-term storage, remove the battery ground (-) cable of each vehicle and reinstall just before delivery to the customer. Locate the current PDS TSB on TIS for complete details. ^ If a hybrid vehicle is put into storage, the state of charge (SOC) of it's battery and auxiliary battery will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage, proper maintenance is necessary. Refer to TSB "Maintenance for HV & Auxiliary Batteries" for procedure and additional information. Tire Inflation Pressure If the vehicle is parked for long periods without being moved, a flat spot may develop on each tire surface in contact with the ground, even if the tires are inflated to specification. Tire inflation pressure should be checked once a month. Tire inflation pressure for storage only: 45 psi. Parts Rust If the vehicles in your storage area are exposed to a sea breeze and/or a significant precipitation corrosion with rust in some parts may occur. If rust is found remove it and treat it by applying rust inhibitor to prevent recurrence. Engine Starting and Vehicle Movement If the vehicle is stored over an extended period of time starting and running the engine periodically will ensure smooth running operation. 1. Start and operate the engine at an engine speed under 1,500 RPM for 15 minutes or longer. This also eliminates moisture in the exhaust system. NOTE Be sure to allow sufficient clearance at the rear of the vehicle to prevent other vehicles stored behind from getting damaged by exhaust gas. 2. Move the vehicle at least 30 feet to lubricate the transmission and differential and prevent tire flat-spot damage. 3. Raise engine speed above 3,000 RPM 10 times to eliminate moisture from the exhaust. A/C Compressor Lubrication To minimize the possibility of damage to the A/C compressor while storing a vehicle perform the following recommended maintenance procedures at Page 3582 Transmission Mode Indicator - A/T: Description and Operation ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR SYSTEM OUTLINE The electronically controlled transmission electrically controls the, throttle pressure, lock-up pressure, and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls the gear shift timing and lock-up timing in response to the vehicle's driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection of the gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. GEAR SHIFT OPERATION When driving, the engine warm up condition is input as a control signal from the engine coolant temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA, VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. LOCK-UP OPERATION When the engine control module decides based on each signal that the lock-up condition has been met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the electronically controlled transmission solenoid to GROUND. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input to TERMINAL STP of the engine control module. As a result, the engine control module cuts the current to the solenoid to release the lock-up. 4. OVERDRIVE CIRCUIT - O/D main SW on When the O/D main SW is switched to ON position, a signal is input to TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range, through the control of the engine control module. - O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range through the control of the engine control module. When in the overdrive range already, shift down is made. Page 712 Camshaft Position Sensor Page 5919 Valve Cover Oil Baffle - Damage Prevention Valve Cover: Technical Service Bulletins Valve Cover Oil Baffle - Damage Prevention ENGINE EG007-02 Title: GENERAL MAINTENANCE TIP Models: All '93 - '03 Models March 22, 2002 Introduction To help prevent unnecessary complications during the oil fill process, no undue load should be placed on the oil baffle attached to the inside of the valve cover (see illustration). This baffle is designed to deflect oil and should not be used to support the weight of heavy oil fill devices. These devices can place stress on the baffle, and bend or break it during the oil fill process. Applicable Vehicles ^ All 1993 - 2003 model year Toyota vehicles. Oil Filling Procedure Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does become damaged, repair it before any collateral damage occurs. Warranty Information Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Tools and Equipment Clutch: Tools and Equipment Clutch - SST (Special Service Tools) Clutch - Recommended Tools Clutch - Equipment Page 4920 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 1929 Page 1684 Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be available. See TIS - Diagnostics - Scantool page for additional information. ^ If using TIS Techstream select TIS Techstream VIM (this is the default). 4. Click OK. Operation Procedure 1. Verify the vehicle's applicability for recalibration and locate desired calibration file. A. Connect Techstream and establish a vehicle connection. B. Click the Health Check button on the System Select tab. Page 6983 Windshield Page 1205 Crankshaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 1073 Engine Room R/B Details Page 4684 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 6981 ^ Allow recommended cure time for urethane bond before delivering vehicle. ^ Always use OEM or manufacturers approved replacement glass and equivalent bonding materials. Page 5756 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 5999 f. Access cab: Using a screwdriver, open the cap. g. Access cab: Unfasten the bolt and remove rear seat outer belt shoulder anchor. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) h. Insert a screwdriver between the quarter trim and body panel to remove the quarter trim. i. Employ the same manner described above to the other side. 16. REMOVE ROOF HEADLINING a. Remove the 2 screws and 2 sun visor holders. b. Standard cab: Remove the 2 clips and roof headlining. c. Access cab: Remove the 3 clips and roof headlining. INSTALLATION Installation is in the reverse order of removal. Page 6823 Horn: Electrical Diagrams Service Hints C16 HORN SW [COMB.SW] 6 - GROUND : Continuity with horn SW on Horn Specifications Tail Gate Page 6561 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 841 Locations Engine Room R/B Page 5217 INSPECT MAGNETIC CLUTCH OPERATION a. Disconnect the connector. b. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to the body ground. c. Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. 13. 2UZ-FE engine INSPECT COMPRESSOR LOCK SENSOR RESISTANCE a. Disconnect the connector. b. Measure resistance between terminals 1 and 2. Standard resistance: 65 - 125 ohms at 20 °C (68 °F) If resistance is not as specified, replace the compressor. Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY a. remove the reservoir tank cap and strainer. b. Disconnect the connector. c. Check that no continuity exists between the terminals with the switch OFF (float up). d. Use siphon, etc. to take fluid out of the reservoir tank. e. Check that continuity exists between the terminals with the switch ON (float down) f. Pour the fluid back in the reservoir tank. If operation is not as specified, replace switch. Page 2538 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 4235 NOTE: If replacing the rear axle shaft and if the vehicle is equipped with ABS, ensure proper installation of the ABS speed sensor rotor and the bearing retainer (differential side). Use SST P/N: 09521-25011-01 to press and install a new sensor rotor and new bearing retainer to the axle shaft (Refer to Figure 2). 4. Replace the rear brake shoes and brake drums. For additional information on rear brake shoes and brake drum replacement, refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Brakes: Rear Drum Brake: Removal/Installation. 5. Adjust the PKB to specifications. 6. Remount the tire and wheel assembly to the vehicle. Torque all wheel nuts to the vehicle according to the vehicle specifications found in TIS: 2000 - 2005 model year Tundra Repair Manual: Brakes: Rear Drum Brake: Removal/Installation. 7. Road test the vehicle to determine if all brake vibration has been eliminated. 8. If brake vibration remains, determine if the vibration is from the front or the rear (while brakes are still warm from confirmation driving). If it is front vibration, refer to TSB No. BR004-02, Front Brake Vibration," for parts and repair information relating to Tundra front brake vibration. Page 6590 Key Reminder Switch: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 4430 3. REMOVE SHACKLES NO. 1 AND NO. 2 (a) Remove the nut washer and bolt, and remove the load sensing spring and 2 plate washers. (b) Loosen the 2 nuts and plate washer plate, and remove the shackle No. 1 from the shackle No. 2. 4. DISASSEMBLE LOAD SENSING SPRING (a) Remove the 4 bushings and 2 collars. (b) Remove the load sensing valve boot and load sensing spring boot. INSPECTION INSPECT VALVE PISTON PIN AND LOAD SENSING CONTACT SURFACE FOR WEAR Wear limit: 0.7 mm (0.028 inch) REASSEMBLY 1. ASSEMBLE LOAD SENSING SPRING (a) Install the load sensing valve boot and load sensing spring boot. Page 6250 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 6179 Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 4. INSTALL TAILGATE HANDLE ASSEMBLY Install the tailgate handle assembly with the 2 bolts. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) 5. INSTALL TAILGATE LOCK a. Using a torx socket wrench, install the 2 tailgate locks with the 4 torx screws. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) b. Connect the 2 tailgate lock links to the tailgate lock control 6. INSTALL SERVICE HOLE COVER Using a torx socket wrench, install the service hole cover with the 8 torx screws. 7. INSTALL TAILGATE PROTECTOR Testing and Inspection Four Wheel Drive Selector Switch: Testing and Inspection INSPECTION 1. INSPECT 2WD -> 4HI SHIFT a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4 switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4 switch is in OFF position. HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be moved back and forth. - If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash. 2. INSPECT 4HI -> 4LO SHIFT Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Brakes - Front Brakes Vibrating Technical Service Bulletin # BR004R-02 Date: 040305 Brakes - Front Brakes Vibrating BRAKES BR004-02 REVISED September 16, 2002 Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra TSB REVISION NOTICE: ^ March 5, 2004: A torque specification in, step 24, was changed. ^ September 8, 2003: A torque specification in, step 28, was changed. The previous TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles ^ 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3889 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 1444 Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 21. INSTALL RH NO.3 TIMING BELT COVER a. Fit the RH No.3 timing belt cover, matching it with the fan bracket. b. Install the RH No.3 timing belt cover with the 3 bolts and nut. Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.) 22. INSTALL LH NO.3 TIMING BELT COVER a. Install the oil cooler pipe with the bolt and nut. b. Run the camshaft position sensor wire through the LH No.3 timing belt cover hole. c. Fit the LH No.3 timing belt cover, matching it with the fan bracket. d. Install the LH No.3 timing belt cover with the 4 bolts and nut. Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.) e. Install the wire grommet to the LH No.3 timing belt cover. f. Install the camshaft position sensor connector to the connector bracket. g. Connect the camshaft position sensor connector. h. Install the sensor wire to the wire clamp on the LH No.3 timing belt cover. i. Install the engine wire to the 2 wire clamps on the LH No.3 timing belt cover. 23. INSTALL DRIVE BELT IDLER PULLEY Install the idler pulley and cover plate with the bolt. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 24. INSTALL PS PUMP Install the PS pump with the 3 bolts. Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.) 25. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT a. Temporarily install the fan pulley, the fan, fluid coupling assembly with the 4 nuts. b. Install the drive belt. c. Tighten the 4 nuts holding the fluid coupling to the fan bracket. Torque: 21 Nm (215 kgf-cm, 16 ft. lbs.) 26. INTAKE AIR CONNECTOR ASSEMBLY 27. INSTALL THROTTLE BODY COVER 28. INSTALL RADIATOR ASSEMBLY 29. FILL WITH ENGINE COOLANT 30. START ENGINE AND CHECK FOR LEAKS Page 4353 SST P/N: 09527-17011 B. Coat MP grease to the oil seal lip. 18. Install new dust cover and axle hub to steering knuckle. A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. SST P/N: 09649-17010 19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is installed completely. 20. 2WD: Install new lock nut. A. Using the following SST, install and torque a NEW lock nut to the axle hub. SST P/N: 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. Locations Instrument Panel Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2157 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Page 606 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 5958 Information PRELIMINARY INSPECTION INSTRUCTIONS Page 623 CHART 16 CHART 17 Page 3903 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 1655 Exhaust Manifold: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 5075 Page 520 Applicable Vehicles Page 1817 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Page 4175 Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. Install shock absorber with coil spring. A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts. A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper, and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. Install new brake line. Using the SST, connect NEW brake line. SST P/N: 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. With ABS: Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: Install drive shaft lock nut. A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: Install grease cap. 31. Install front wheel. NOTE: Do NOT use an air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) Page 1023 Engine Oil: Service and Repair REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. w/ Oil filter change: REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil drain plug and gasket, and drain the oil into a container. 3. REPLACE OIL FILTER a. Using SST, remove the oil filter. SST 09228-07501 b. Clean the oil filter contact surface on the oil filter mounting. c. Lubricate the filter rubber gasket with clean engine oil. d. Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. e. Using SST, give it an additional 3/4 turn to seat the filter. SST 09228-07501 Page 4630 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5402 c. Using a service-purpose wire harness, tie down the steering wheel pad to the disc wheel. Wire harness : Stripped wire harness section 1.25 sq.mm or more (0.0019 sq.in. or more). CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 sq.mm (0.0019 sq.in). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 * sq.(Diameter) divided by 4 1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L : 35.0 mm (1.387 in.) M : 6.0 mm (0.236 in.) Pitch : 1.0 mm (0.039 in.) NOTE: Tighten the bolts by hand until the bolts become difficult to turn. - Do not tighten the bolts too much. Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Torque ............................................................................................................. .................................................... 245 Nm (181 ft.lb) Page 1069 Interior Panel Fuse Details Page 407 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2900 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2747 Locations Anti-Lock Brake System Page 6822 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Locations Intake Air Temperature Sensor: Locations Mass Air Flow (MAF) Meter The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Locations Vapor Pressure Sensor Page 4070 INSTALL NEW OIL SEAL (INSIDE) A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. INSTALL STEERING KNUCKLE A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. CONNECT LOWER BALL JOINT Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. INSTALL SHOCK ABSORBER WITH COIL SPRING A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. 09023-00100 Page 3136 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Page 2588 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 3352 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 3139 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Page 1752 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 2448 CHART 30 Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 4992 d. Install the SST. CAUTION: Place the disc wheel on the level ground. 1. Connect the connectors of the 2 SST to the steering wheel pad connector. SST 09082-0700, 09082-0760 NOTE: 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. 2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. e. Cover the steering wheel pad with a cardboard box or tires. - Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire - If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. - Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions- Width: 185 mm (7.87 in.) Page 4050 9. Remove steering knuckle. A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: Remove grease cap. A. Mount the axle hub in a soft jaw vise. NOTE: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). B. Using a screwdriver, remove the grease cap. NOTE: Be careful not to damage the grease cap. Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for no more than 5 - 10 seconds at a time. If the spark does not occur, do the test as per the given flow chart. 7. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) 8. Reinstall the ignition coils (with igniter). Component Tests and General Diagnostics Brake Light Switch: Component Tests and General Diagnostics w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. w/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Locations Relay Box: Locations Driver Side J/B And Integration Relay Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 1226 a. Check only the valves indicated. - Using a feeler gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 10. ADJUST VALVE CLEARANCE a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim. d. Determine the replacement adjusting shim size according to these Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T .......................................................................................................................................................... ................. Thickness of removed shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Page 3667 b. Grind the retainer and sensor rotor surfaces, then chisel them out. c. Attach washers and nuts to the serration bolts, then torque the nuts to install the serration bolts to the backing plate. d. Remove the 4 nuts and washers from the serration bolts. 2. REMOVE SNAP RING FROM AXLE SHAFT Using a snap ring expander, remove the snap ring. 3. REMOVE REAR AXLE SHAFT FROM BACKING PLATE a. Position Special Service Tool (SST) on the backing plate with the 4 nuts. SST 09521-25011 b. Using a press, remove the rear axle shaft and bearing retainer from the backing plate. c. Remove the SST SST 09521-25011 4. INSPECT AXLE SHAFT Using a dial indicator, measure the runout of the shaft and flange. Maximum shaft runout: 2.0 mm (0.079 inch) Maximum flange runout: 0.1 mm (0.004 inch) If the rear axle shaft or flange are damaged or worn, or if runout is greater than the maximum, replace the rear axle shaft. 5. INSPECT OIL SEAL (OUTER SIDE) a. Check for damage. b. Check the oil seal lip for wear or damage. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 3709 a. Align the matchmarks on the propeller shaft and differential flanges, and connect the flanges with the 4 bolts, washers and nuts. b. Torque the 4 bolts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) c. Temporarily install the center support bearing with 2 mount bolts. HINT: Make sure the bearing is installed with the drain hole facing downwards. d. Align the matchmarks on the propeller shaft and transfer flanges, and connect the flanges with the 4 nuts and washers. e. Torque the 4 nuts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) 3. ADJUST CENTER SUPPORT BEARING HINT: - With the vehicle unladen, adjust the center support bearing to keep the intervals. - In the same condition, check the center line in the axial direction. Adjust the bearing if necessary. - Center bearing center line and center bearing housing center line must be adjusted to within 0 ± 1.0 mm of each other in the vehicle's longitudinal direction when the vehicle is unloaded. Torque the 2 bolts. Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.) Page 6350 Glossary Of Terms And Symbols (Part 1) Page 5085 Diagrams Steering Gear: Diagrams POWER STEERING GEAR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Part 1 of 3 Page 1267 12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding the bracket forward (refer to illustration). 13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following sequence: bolt 2, bolt 1, bolt 3. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) 14. Remove the accessory drive belt tensioner. 15. Install the NEW accessory drive belt tensioner. 16. Reassemble in the reverse order of disassembly. 17. Refill cooling system. Page 4957 12. REMOVE CONTROL VALVE ASSEMBLY a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. b. Press out the valve assembly with the oil seal. NOTICE: ^ Place a shop rag between the valve housing and the blocks. ^ Be careful not to drop the valve assembly. ^ Be careful not to damage the oil seal lip. 13. REMOVE OIL SEAL Remove the oil seal from the control valve assembly. 14. REMOVE CYLINDER END STOPPER a. Using SST, turn the stopper clockwise until the wire end is visible through the service hole. SST 09631-16010 b. Using SST, turn the stopper counterclockwise, and remove the wire. SST 09631-16010 15. REMOVE STEERING RACK AND BUSHING a. Using SST, press out the steering rack with the bushing NOTICE: Take care not to drop the rack. SST 09950-70010 (09951-07200) b. Remove the bushing from the rack. c. Remove the O-ring from the bushing. Page 195 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 6498 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 5589 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 726 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 5076 Information PRELIMINARY INSPECTION INSTRUCTIONS Page 4960 f. Using SST, press in the bearing. SST 09950-60010 (09951-00320), 09950-70010 (09951-07150) 3. IF NECESSARY, REPLACE OIL SEAL a. Using SST, remove the oil seal from the bushing. SST 09527-20011, 09612-24014 (09613-22011) NOTICE: Be careful not to damage the bushing. b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00300, 09951-00460, 09952-06010) NOTICE: Make sure to install the oil seal facing in the correct direction. 4. IF NECESSARY, REPLACE TEFLON RING AND O-RING a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack. NOTICE: Be careful not to damage the groove for the Teflon ring. b. Coat a new O-ring with power steering fluid and install it to steering rack. Page 5464 2. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the airbag sensor assembly connectors. NOTE: Disconnect the connectors with the sensor assembly installed. b. Using a torx wrench, remove the 4 screws. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) c. Remove the airbag sensor assembly. INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. - Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. - Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with 4 screws. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) b. Connect the airbag sensor connectors. NOTE: Connection of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed with the specified torque. - If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. - When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installing , shake the sensor assembly to check that there is no looseness. 2. INSTALL LOWER CENTER COVER Page 4912 Splice Location B11 Page 2325 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Page 4438 3. DISCONNECT BRAKE LINES Using SST, disconnect the 5 or 6 brake lines from the master cylinder and 3-way or 4-way. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 4. REMOVE MASTER CYLINDER (a) w/ ABS: Remove the 2 nuts, wire harness bracket 3-way and check valve bracket. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (b) w/o ABS: Remove the 2 nuts, wire harness bracket 4-way and check valve bracket. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) (c) Pull out the master cylinder from brake booster. INSTALLATION Installation is in the reverse order of removal. HINT: Before installation, adjust length of brake booster push rod. - After installation, fill brake reservoir with brake fluid and bleed brake system. - Check for leaks, check and adjust brake pedal. Page 2874 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 5963 Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 6584 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 6227 b. Check the DTC. HINT: If a malfunction occurs in the speed sensor or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and turns ON and OFF the CRUISE MAIN indicator light to inform the driver of a malfunction. At the same time, the malfunction is stored in memory as a diagnostic trouble code. c. Output DTC using diagnosis check wire. 1. Turn the ignition switch ON. 2. Using SST connect terminals Tc and CG of DLC3. SST 09843-18020 3. Read the DTC on the CRUISE MAIN indicator light. HINT: If the DTC is not output, inspect the diagnosis circuit. As an example, the blinking patterns for codes; normal 52 are shown in the illustration. Page 39 Engine Room R/B Page 6804 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 6874 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 950 Drive Belt: Testing and Inspection INSPECTION INSPECT DRIVE BELT a. Visually check the belt for excessive wear, frayed cords, etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the ribs are found on the belt, it should be replaced. b. 5VZ-FE engine: Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension: New belt: 135 - 180 lbs. Used belt: 85 - 120 lbs. If the belt tension is not as specified, adjust it. HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing a 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 pulley. - After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. Locations Daytime Running Lamp Relay: Locations Instrument Panel Page 3147 1. DISCONNECT IGNITION COIL (WITH IGNITER) CONNECTORS 2. REMOVE IGNITION COILS (WITH IGNITER) FROM SPARK PLUGS Remove the bolt, and pull out the ignition coil (with igniter). Remove the 8 ignition coils (with igniter). INSTALLATION 1. INSTALL IGNITION COILS (WITH IGNITER) TO SPARK PLUGS Install the ignition coil (with igniter) with the bolt. Install the 8 ignition coils (with igniter). Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. CONNECT IGNITION COIL (WITH IGNITER) CONNECTORS Page 3845 6. INSPECT LIMIT SWITCH CONTINUITY a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the transfer shift lever and after checking the operating sound, disconnect the connector and inspect the continuity between each terminal. HINT: When shifting the actuator fork shaft, connect the connectors. 7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check the combination meter. 9. INSPECT 4WD CONTROL ECU Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side connector from the back side. Page 670 Glossary Of Terms And Symbols (Part 1) Seat Belts - Shoulder Belt Particle (Dirt) Buildup Seat Belt: All Technical Service Bulletins Seat Belts - Shoulder Belt Particle (Dirt) Buildup BODY BO019-01 August 10, 2001 Title: SHOULDER BELT ANCHOR TAPE SET Models: All Applicable Models Introduction To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor, the following procedure has been developed. Applicable Vehicles ^ 1996-2001 model year 4Runner*1 vehicles. ^ 1996-2001 model year Land Cruiser vehicles. ^ 1996-2001 model year RAV4*2 vehicles. ^ 2001 model year Sequoia vehicles. ^ 1996-1998 model year T100 trucks. ^ 1996-2001 model year Tacoma*1 trucks. ^ 2000-2001 model year Tundra trucks. *1 Except rear seat belt. *2 Except rear seat belt of soft top models. Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Installation Procedure 1. CLEAN SHOULDER BELT ANCHOR NOTE: ^ Do not install the tape when the vehicle temperature is below the freezing point. ^ Do not re-use removed fluorocarbon resin tape. Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 4618 Driver Side J/B And Integration Relay Fuse Applications (Part 2) Driver Side J/B And Integration Relay Fuse Applications (Part 3) Page 1512 4. REMOVE WATER INLET AND INLET HOUSING ASSEMBLY a. Disconnect the water bypass hose from the water inlet housing. b. Remove the 2 bolts holding the water inlet housing to the water pump. c. Disconnect the water inlet housing from the front water bypass joint, and remove the water inlet and inlet housing assembly. d. Remove the O-ring from the water inlet housing. 5. REMOVE WATER PUMP a. Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. b. Remove the O-ring from the water bypass pipe. INSPECTION 1. INSPECT WATER PUMP a. Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump and timing belt. b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING a. Remove the 4 nuts and fan from the fluid coupling. Testing and Inspection Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise, check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Page 3461 Glossary Of Terms And Symbols (Part 1) Page 5345 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION SEAT BELT SYSTEMS CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill-bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. PRETENSIONER IS NOT ACTIVATED a. Perform a diagnostic system check. * b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Standard cab: Check for cuts and cracks in, or marked discoloration on the quarter trim. - Access cab: Check for cuts and cracks in, or marked discoloration on the front door rear scuff plate. - Check for cuts and cracks in wire harness, and for chipping in connectors. Page 4733 Engine Room R/B Fuse Applications (Part 2) Engine Room Fuse Details Page 2078 Camshaft Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. Resistance b. Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the camshaft position sensor. c. Reconnect the camshaft position sensor connector. Specifications Crankshaft: Specifications Crankshaft Crank Pin Diameter Mark 1 ............................................................................................... ..................................................................................................... 51.994 - 52.000 mm Mark 2 .......... .............................................................................................................................................................. ............................ 51.988 - 51.994 mm Mark 3 ................................................................................... ................................................................................................................. 51.982 - 51.986 mm Crankshaft Thrust Clearance Standard ............................................................................................... ...................................................................................................... 0.020 - 0.220 mm Maximum ......... .............................................................................................................................................................. .......................................... 0.30 mm Thrust Washer Thickness .......................................................... ................................................................................................................. 2.440 - 2.490 mm Crankshaft Maximum Circle Runout .................................................................................................... .................................................................... 0.08 mm Main Journal Diameter ........................................................................................................................ .................................................. 66.988 - 67.000 mm Crank Pin Diameter ......................................... ....................................................................................................................................... 51.982 52.000 mm Maximum Taper and Out-Of-Round ................................................................................. ....................................................................................... 0.02 mm Page 5216 Compressor Clutch: Testing and Inspection COMPRESSOR AND MAGNETIC CLUTCH ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. START ENGINE 3. INSPECT COMPRESSOR FOR METALLIC SOUND Check if there is a metallic sound from the compressor when the A/C switch is on. If metallic sound is not heard, replace the compressor assembly. 4. INSPECT REFRIGERANT PRESSURE 5. STOP ENGINE 6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEAL Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 7. SET OFF MANIFOLD GAUGE SET 8. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING 9. CHECK FOR SIGNS OF OIL ON PRESSURE PLATE If necessary, repair or replace. 10. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE a. Start engine. b. Check for abnormal noise from near the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the magnetic clutch. 11. 5VZ-FE engine INSPECT MAGNETIC CLUTCH OPERATION a. Disconnect the connector. b. Connect the positive (+) lead from the battery to terminal on the magnetic clutch connector and the negative (-) lead to the body ground. c. Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. 12. 2UZ-FE engine Page 4958 16. REMOVE OIL SEAL Using SST, press out the oil seal. SST 09950-60010 (09951-00360), 09950-70010 (09951-07360) INSPECTION INSPECT STEERING RACK a. Using a dial indicator, check the rack for runout, teeth wear and damage. Maximum runout: 0.03 mm (0.0118 inch) b. Check the back surface for wear and damage. REPLACEMENT NOTICE: When using a vise, do not overtighten it. 1. IF NECESSARY, REPLACE OIL SEAL AND BEARING a. Using SST, press out the oil seal and bearing from the control valve housing. SST 09950-60010 (09951-00250), 09950-70010 (09951-07150) b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150) Page 2035 Glossary Of Terms And Symbols (Part 2) Page 2264 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 1638 Part 2 of 3 Page 5909 FOR SPECIAL SERVICE CAMPAIGN REAR FRAME CROSS MEMBER & LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION 2000-2003 MODEL YEAR TUNDRA Page 4505 Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY Remove the relay box cover and starter relay. 2. INSPECT STARTER RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 3. INSPECT STARTER RELAY OPERATION a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL STARTER RELAY Page 3337 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Page 1499 a. Check only the valves indicated. - Using a feeler gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 10. ADJUST VALVE CLEARANCE a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim. d. Determine the replacement adjusting shim size according to these Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T .......................................................................................................................................................... ................. Thickness of removed shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Page 2986 2. Tighten the union bolt by hand. 3. Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. Page 4809 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 6552 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Front Wheel Bearing: Service and Repair Front Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION FRONT PASSENGER AIRBAG ASSEMBLY VEHICLE NOT INVOLVED IN COLLISION a. Do a diagnostic system check. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes b. Do a visual check which includes the following item with the front passenger airbag assembly installed in the vehicle. Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly and instrument panel. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a. Do a diagnostic system check. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes b. Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle. - Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly. - Check cuts and cracks in wire harnesses, and for chipping in connectors. - Check the deformation or cracks on the instrument panel and 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. Page 4715 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 62 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 5286 Heater Control Valve: Service and Repair WATER VALVE REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE HINT: At the time of installation, please refer to the following item. After connection, adjust the control cable. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the hose clip and slide the hose clip along the hose. b. Disconnect the water hoses. HINT: At the time of installation, please refer to the following item. Heater radiator pipe: Push the water hose onto the heater radiator pipe as far as second ridge on the pipe. - Water valve: Push the water hose onto the water valve pipe as far as water valve. - Install the hose clip in a position, as shown in the illustration. Page 4797 Engine Compartment Instrument Panel Locations Page 3578 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4872 REMOVAL 1. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE a. Disconnect the MAF meter connector. b. Disconnect the hoses. c. Remove the clamp. d. Remove the 3 bolts and air cleaner assembly with air cleaner hose. Page 6558 Seat Belt Reminder Lamp: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6351 Glossary Of Terms And Symbols (Part 2) Page 5901 Page 2427 CHART 12 CHART 13 Page 953 Assenmacher Specialty Tools 1-800-525-2943 Locations Supplemental Restraint System Page 4338 Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. ^ 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 1794 Terminals Of ECU - Connector Pinouts (Part 2) Page 2773 CHART 26 Testing and Inspection Oil Filter: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection; Procedures. Page 790 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 6409 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 6967 a. Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table. b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive as shown in the illustration. A: 8.0 mm (0.314 in.) B: 12.0 mm (0.472 in.) 7. Slide type: APPLY ADHESIVE Page 272 Airbag Sensor Assembly: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 3703 Drive/Propeller Shaft: Testing and Inspection PROBLEM SYMPTOMS TABLE Use the table 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 order. If necessary, replace these parts. Page 4740 Engine Room R/B Details Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 4512 Above are items that should be checked periodically and their frequency. Summary Chart for Long-Term Storage A combination of proper Vehicle Receipt, Pre-Delivery Service and Vehicle Storage is the only way to maintain factory fresh vehicles. Toyota's goal is to deliver 100% problem-free cars and trucks. With your commitment to quality and customer satisfaction, we can reach that goal. Review this TSB often and be sure new employees are aware of the policies and procedures out-lined herein, as individual training in proper inspection, pre-delivery service, and storage and handling techniques are essential to ensure high delivery quality. Here is a list of additional resources, which will help you with vehicle receipt, inspection and storage procedures. Reference and Training Materials ^ CRIB # 165, Acid Rain Paint Finish Damage - Prevention and Repair ^ UoT e-Learning Course E257 Vehicle Delivery Quality - Paint Finish Repair ^ Dealer Delivery Quality Operations Guide, P/N 00116-DDQ0G-98 ^ BO020-91, Prevention and Repair of Acid Rain Damage ^ BO05-04, New Vehicle Washing Schedule for Paint Protection ^ PG001-06, Battery Maintenance for In Stock Vehicle and Pre-Delivery ^ PA005-04, Iron Particle Rust Contamination Repair ^ PG005-94, Rapgard(TM) Removal Procedures ^ PG007-02, Wheel Film for Brake Rotor Rust Prevention ^ Maintenance for HV & Auxiliary Batteries, Refer to applicable HV models. Specifications Valve Body: Specifications Valve Body Spring Upper Valve Body Lock-Up Relay Valve Red Free Length 23.42 mm Coil Outer Diameter 4.66 mm Total No. Of Coils 12.25 Secondary Regulator Valve Purple Free Length 32.88 mm Coil Outer Diameter 8.2 mm Total No. Of Coils 9.13 3-4 Shift Valve Purple Free Length 30.77 mm Coil Outer Diameter 9.7 mm Total No. Of Coils 8.5 2-3 Shift Valve Purple Free Length 30.77 mm Coil Outer Diameter 9.7 mm Total No. Of Coils 8.5 2nd Coast Modulator Valve Blue Free Length 24.55 mm Coil Outer Diameter 8.32 mm Total No. Of Coils 9 Low Coast Modulator Yellow Free Length 26.43 mm Coil Outer Diameter 8.26 mm Total No. Of Coils 10.51 Lower Valve Body Primary Regulator Valve White Free Length 38.58 mm Coil Outer Diameter 16.88 mm Total No. Of Coils 9.5 Cut Back Valve None Free Length 33.95 mm Coil Outer Diameter 8.2 mm Total No. Of Coils 12.5 Solenoid Modulator Valve Light Blue Free Length 26.60 mm Coil Outer Diameter 5.89 mm Total No. Of Coils 12.0 Accumulator Control Valve None Free Length 33.81 mm Coil Outer Diameter 9.7 mm Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 6226 e. Inspect the RES (resume) switch. 1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset. - Depress the brake pedal. - Shift into except D position. - Pull the cruise control switch for CANCEL. 4. After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed before the cancellation. Clearing Diagnostic Trouble Codes NOTE: This is the only information provided by the manufacturer for Clearing Diagnostic Trouble Codes for this system. DTC CLEARANCE a. The following actions will erase DTCs and freeze frame data. 1. Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand-held tester to erase codes. (See the OBD II scan tool's instruction book for operating instructions.) 2. Disconnecting the battery terminals or EFI fuse. b. After completing repairs, the DTC retained in the memory can be cleared by removing the ECU-B fuse for 10 seconds or more with the ignition switch OFF. c. Check that the normal code is displayed after connecting the fuse. Displaying & Reading Trouble Codes NOTE: This is the only information provided by the manufacturer for reading diagnostic trouble codes for this system. 1. DIAGNOSIS SYSTEM a. Check the indicator. 1. Turn the ignition switch to ON. 2. Check that the CRUISE MAIN indicator light comes on when the cruise control main switch is turned ON, and that the indicator light goes off when the main switch is turned OFF. HINT: If the indicator check result is not normal, proceed to troubleshooting for the combination meter section. Page 5355 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTE: Page 5214 Compressor Clutch: Diagrams Compressor And Magnetic Clutch (Part 1) Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 4628 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 637 CHART 27 Page 5634 HINT: Tape the screwdriver tip before use. d. Remove the bolt and front seat outer belt floor anchor. e. Remove the quarter trim. 1. Using a screwdriver, remove the quarter trim belt hole cover. HINT: Tape the screwdriver tip before use. 2. Using a screwdriver, remove the cap. HINT: Tape the screwdriver tip before use. 3. Remove the bolt and front seat outer belt shoulder anchor. 4. Using a screwdriver, remove the quarter trim. HINT: Tape the screwdriver tip before use. f. Remove the retractor of front seat outer belt. CAUTION: Never disassemble the front seat outer belt. NOTE: When removing the retractor of front seat outer belt, take care not to pull the seat belt pretensioner wire harness. Page 4441 NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows. Page 3732 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 1213 Piston: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 5694 Page 4224 Brake Rotor/Disc: Testing and Inspection For information regarding the inspection of this component, please refer to Brake Caliper; Service and Repair; Disassembly and Reassembly. Locations Vapor Pressure Sensor Page 6438 Key Reminder Switch: Pinout Values and Diagnostic Parameters KEY REMINDER AND SEAT BELT WARNING B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Page 4363 Repair Procedure 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. Page 1029 Steering - Lubricant Page 2299 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 6510 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 2315 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 3100 Throttle Body (Part 2) REMOVAL 1. REMOVE THROTTLE BODY COVER 2. DRAIN ENGINE COOLANT Page 3663 6. REMOVE DUST COVER Using SST and a press, remove the dust cover. SST 09950-00020 REASSEMBLY 1. INSTALL DUST COVER Using a screwdriver and hammer, install a new dust cover. 2. INSTALL DUST SEAL Using a screwdriver and hammer, install a new dust seal. 3. TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND NEW BOOT CLAMPS HINT: ^ Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from bearing damaged. ^ Before installing the boots, place 3 new clamps to the small boot ends and large boot end (outboard joint side). 4. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT Align the matchmarks; placed before disassembly, and using a snap ring expander, put in the inboard joint shaft while expanding the snap ring. 5. INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot, pack the outboard joint and boot with grease in the boot kit. Grease capacity (Color = Black): 205 - 225 g (7.23 - 7.94 oz.) 6. INSTALL BOOT TO INBOARD JOINT SHAFT a. Pack the inboard joint and boot with grease in the boot kit. Page 269 Airbag Sensor Assembly: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the lower center cover. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor and judges whether the SRS must be activated or not. Page 2371 Page 677 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2914 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Page 5301 Hose/Line HVAC: Service and Repair REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system 3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TORQUE NOTE: Connections should not be torqued tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT AIR CONDITIONING OPERATION Page 5445 Steps 1 - 2 INSPECTION PROCEDURE SRS (Does Not Light Up, When Ignition Switch Is on ACC Or On) SRS Warning Light Circuit Malfunction (Does not light up, when ignition switch is turned to ACC or 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 ACC or 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 E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS warning light. Page 5729 Glossary Of Terms And Symbols (Part 1) Page 6838 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2743 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 4669 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 6204 Cruise Control: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 6106 INSPECT POWER SEAT SWITCH CIRCUIT a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. b. Inspect the connector on the wire harness side. If circuit is not as specified, inspect the circuits connected to other parts. INSPECT LUMBAR SUPPORT SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT LUMBAR SUPPORT SWITCH CIRCUIT a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. Page 5062 Page 3843 5. INSPECT ACTUATOR OPERATION a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD -> 4HI position. b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 2WD position. Page 5978 Perform the procedure shown if there is any lamp malfunction. Page 6078 CLADDING CODE FORMULA TUNDRA TWO-TONE COMBINATION CAMRY GALLERY SERLES (Special Edition) Page 5542 Part Number Information Owner Instructions Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. ^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. Diagrams Page 4454 Parking Brake Pedal: Service and Repair REMOVAL 1. REMOVE SCUFF PLATE LH, COWL SIDE TRIM LH, LOWER FINISH PANEL AND NO. 2 HEATER TO REGISTER DUCT 2. REMOVE PARKING BRAKE PEDAL ASSEMBLY (a) Disconnect the parking brake switch connector. (b) Remove the lock nut and adjusting nut from the parking brake wire. (c) Remove the clip and parking brake wire. (d) Remove the 4 bolts and parking brake pedal assembly. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After the installation, check and adjust parking brake pedal travel. Page 5848 Front Door (Part 2) Page 2087 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Page 1737 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Page 4604 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ...................................................... 1,324 kPa or More Minimum Pressure ......................................... ........................................................................................................................................................... 981 kPa Difference Between Each Cylinder ........................................................................................ ......................................................................... 98 kPa or Less Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 5200 After connection, adjust the control cable. c. Remove the nut, bolt and blower unit. INSTALLATION Installation is in the reverse order of removal. Page 2192 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Page 3745 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 3952 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Service and Repair Cylinder Head Gasket: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 5560 Splice Location B11 Page 1838 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. Page 3138 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Page 921 31. RECHECK ENGINE COOLANT LEVEL 32. INSTALL ENGINE UNDER COVER Specifications Case: Specifications Transmission Case Transmission Case Bushing Maximum 38.19 mm Parking Lock Pawl Bracket x Transmission Case 7.4 Nm Transmission Case Plug x Transmission Case 5.4 Nm Page 5540 Front Seat Belt Extender Applications Page 2913 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 1641 Page 329 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Ground Locations Trailer Connector: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 3452 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 2937 2. Apply battery positive voltage across the terminals. 3. Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Page 4546 2. INSTALL PS VANE PUMP 3. INSTALL DRIVE BELT Install the belt by turning the belt tensioner counterclockwise. HINT: The pulley bolt for the belt tensioner has a left-hand thread. 4. PERFORM ON-VEHICLE INSPECTION 5. INSTALL NO.2 FAN SHROUD Install the No.2 fan shroud with the 2 clips. 6. INSTALL ENGINE UNDER COVER Locations Vehicle Lift And Support Locations Page 5084 Page 1442 13. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY a. Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley. 14. SET TIMING BELT TENSIONER a. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbs.) of pressure. b. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. c. Release the press. d. Install the dust boot to the belt tensioner. 15. INSTALL TIMING BELT TENSIONER a. Temporarily install the belt tensioner with the 2 bolts. b. Alternately tighten the 2 bolts. Torque: 26 Nm (270 kgf-cm, 19 ft. lbs.) c. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner. 16. CHECK VALVE TIMING a. Temporarily install the crankshaft pulley bolt. b. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTICE: Always turn the crankshaft pulley clockwise. Page 1596 5. When using the radiator cap tester, tilt it more than 30 degrees. 6. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Page 3950 Vehicle Speed Sensor NO.2 Page 2490 CHART 20 Page 5425 1. LH: REMOVE FRONT AIRBAG SENSOR a. 2UZ-FE: Remove the battery carrier, battery and battery tray. b. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with sensor assembly installed. c. Remove the 2 bolts and front airbag sensor. 2. RH: REMOVE FRONT AIRBAG SENSOR a. Remove the air cleaner assembly. b. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with sensor assembly installed. c. Remove the 2 bolts and front airbag sensor. INSTALLATION INSTALL FRONT AIRBAG SENSORS Page 746 Supplemental Restraint System Page 3331 The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1). NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Figure 2). Operation Procedure LOCATE CALIBRATION FILE The following steps in this bulletin describe how to properly flash reprogram an ECU. 1. Locate calibration file on TIS. Calibration files may be found in two areas (see Figure 3): A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue. ^ Within the TSB, click on the link for the calibration file. B. Search by model under the ECU Flash Reprogramming Section. ^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration files will be displayed. C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card. Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch Page 5717 Splice Location B11 Page 5865 Wheel Arch Moulding Page 1506 Water Pump: Diagrams WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Part 1 of 3 Page 6159 INSPECT POWER SEAT SWITCH CIRCUIT a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. b. Inspect the connector on the wire harness side. If circuit is not as specified, inspect the circuits connected to other parts. INSPECT LUMBAR SUPPORT SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT LUMBAR SUPPORT SWITCH CIRCUIT a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. Page 2296 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Page 1734 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 4813 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4380 Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. ^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). Brakes - Vibration From Front Brakes Technical Service Bulletin # BR004R-02 Date: 040924 Brakes - Vibration From Front Brakes BRAKES BR004-02 REVISED Title: FRONT BRAKE VIBRATION Models: '00 - '03 Tundra September 16, 2002 TSB REVISION NOTICE: ^ September 24, 2004: A note has been added, step 26. ^ March 5, 2004: A torque speification, step 24, was changed. ^ September 8, 2003: A torque specification, step 28, was changed. Previous versions of this TSB should be discarded. Introduction Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved brake caliper assemblies have been introduced to correct this condition. Applicable Vehicles 2000 - 2003 model year Tundra trucks built before the VIN shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 6512 Seat Belt Reminder Buzzer: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Service and Repair Transmission Temperature Sensor/Switch: Service and Repair ON-VEHICLE REPAIR 1. 5VZ-FE: DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission. 2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 4. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR NOTICE: Be careful not to twist the wire harness. 6. CONNECT OIL COOLER PIPE a. Install the elbow to the transmission. Page 5776 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 6268 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Body - Plastic Bumper Refinishing Rear Bumper Cover / Fascia: Technical Service Bulletins Body - Plastic Bumper Refinishing TITLE: PLASTIC BUMPER REFINISHING SECTION: REFINISH BULLETIN # 170 MODELS: ALL TOYOTA LEXUS and SCION DATE: OCTOBER 2008 When it is necessary to replace a damaged plastic bumper, proper consideration should be given to preparation and refinishing to ensure high quality, long-term durability, and customer satisfaction. While it is important to follow paint manufacturer recommendations for application of refinish materials, this bulletin provides Toyota recommended procedures for cleaning and preparation of original equipment (OE) raw plastic bumpers. Background: Toyota bumper covers are manufactured using several types of plastic however, cleaning and preparation procedures outlined here are applicable to all Toyota, Lexus, and Scion raw plastic OE bumpers. Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile organic compound (VOC) emissions produced by the use of cleaning solvents. This topic is covered in Collision Repair Information Bulletin (CRIB) #69. Thorough cleaning with recommended soap and water removes soap-base mold release agent. Cleaning and Preparation: ^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap solution. Rinse well and dry with clean towels. Cleaning and Preparation, Continued^ Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic parts cleaner or water-base wax and grease remover, or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint manufacturer), with sanding paste and clean water. Repeat wash sequence, rinse well and dry with clean towels. ^ Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not appear to have been scuffed sufficiently. Repeat wash- rinse-dry sequence. ^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Apply anti-static measures. ^ Apply adhesion promoter per paint manufacturer7s recommendations. ^ Apply primer and topcoats per paint manufacturer7s recommendations. Note: Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to ensure adhesion, flexibility, and long-term durability of topcoats; and the use of refinish materials that meet or exceed the Toyota new vehicle limited paint finish warranty. Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer). This type of plastic requires the use of adhesion Page 667 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2282 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 1428 Part 2 of 4 Part 3 of 4 Page 3233 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2793 Applicable Vehicles Page 1938 Page 2120 e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time. 4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away. 5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag. g. Observe these precautions when connecting the fuel tube connector (quick type): 1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe. Page 1266 1. Remove the engine under cover. 2. Drain the engine coolant. 3. Remove the intake air connector assembly. 4. Remove the radiator fan shroud. 5. Remove the drive belt, fan, fluid coupling, and fan pulley. 6. Without disconnecting the power steering fluid lines, remove the power steering pump. HINT: Suspend the power steering pump securely. 7. Remove the drive belt idler pulley. 8. Remove the right hand (RH) No. 3 timing belt cover. 9. Remove the No.2 timing belt cover. 10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting bracket. HINT: Suspend the A/C compressor securely. 11. Disconnect the A/C compressor mounting bracket. Page 3670 15. REPLACE OIL SEAL (INNER SIDE) a. Using SST, remove the oil seal. SST 09308-00010 b. Using SST and a hammer, install a new oil seal. SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) c. Coat a new oil seal lip with MP grease. INSTALLATION 1. INSTALL NEW O-RING TO REAR AXLE HOUSING 2. INSTALL REAR AXLE SHAFT ASSEMBLY Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.) 3. CONNECT BRAKE LINE AND PARKING BRAKE CABLE a. Connect the parking brake cable with the pin and clip. b. Using Special Service Tool (SST), connect the brake line to the wheel cylinder. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 4. INSTALL REAR BRAKE ASSEMBLY 5. w/ ABS: INSTALL ABS SPEED SENSOR Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.) 6. CHECK BEARING BACKLASH AND AXLE SHAFT DEVIATION 7. INSTALL NEW GASKET AND BRAKE DRUM 8. INSTALL REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 9. BLEED BRAKE SYSTEM 10. w/ ABS: CHECK ABS SPEED SENSOR SIGNAL Page 2920 Three-Way Catalytic Converter (TWC) System Page 750 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Engine Controls - Error When Reprogramming ECU PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Page 2867 Glossary Of Terms And Symbols (Part 2) Page 4719 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4864 j. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. k. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: ^ Do not maintain lock position for more than 10 seconds. ^ Do not let the fluid temperature become too high. l. Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) m. Connect the pressure feed tube. n. 5VZ-FE engine: Install the air cleaner assembly. o. 2UZ-FE engine: Install the air cleaner assembly with air cleaner hose. p. Bleed the power steering system. Page 3629 Differential Lock: Testing and Inspection INSPECTION 1. INSPECT A.D.D. ACTUATOR a. Disconnect the actuator connector. b. Measure the resistance between the terminals 2 and 6. Standard resistance: 0.3 - 100 ohms c. Measure the resistance between the terminals 2 or 6 and body ground. Page 2141 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Testing and Inspection Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the switch. Page 3104 NOTE: After turning the ignition switch ON, do not depress the accelerator pedal. 4. While reading the value of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA, turn the throttle position sensor slowly to left and right and set the sensor at the center value of the standard value, and then tighten the screws. Standard throttle valve opening percentage: 14.4 - 16 % Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf) 5. Recheck throttle valve opening percentage. If the throttle valve opening percentage is not as specified, repeat step (4). 6. Perform fully closed throttle valve by hand and check that the valve of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA stays with the standard value. Standard throttle valve opening percentage: 10 - 14 % If the throttle valve opening percentage is not as specified, repeat steps (4) to (6). 7. Paint the 2 set screws. 8. Turn the ignition switch OFF. 9. Disconnect the TOYOTA hand-held tester or OBD II scan tool from the DLC3. 10. Disconnect the throttle position sensor connector. 2. REPLACE THROTTLE CONTROL MOTOR a. Remove the throttle position sensor. (See step 1) b. Remove the throttle control motor. 1. Disconnect the throttle control motor connector from the connector bracket. 2. Remove the 6 screws, the throttle control motor cover, motor assembly and washer. 3. Remove the 3 screws, throttle control motor and wave washer from the throttle control motor cover. c. Reinstall a new throttle control motor. Page 506 Knock Sensor (Part 2) Page 2705 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Page 4120 B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 ^ 09527-17011 B. Coat MP grease to the oil seal lip. 18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. 09649-17010 19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 4607 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4045 Parts Information Page 989 Coolant: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT a. Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. Remove the 3 drain plugs on the engine and radiator, and drain the coolant. c. Close the 3 drain plugs. Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.) for engine 3. REFILL WITH ENGINE COOLANT a. Slowly fill the system with coolant. ^ Use of improper coolants may damage engine cooling system. ^ Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the manufacturer's directions. ^ Use of the coolant which includes more than 50% [freezing protection down to -35°C (-31°F)] or 60% [freezing protection down to -50°C (-58°F)] of ethylene-glycol is recommended, but not more than 70%. NOTICE: ^ Do not use an alcohol type coolant or plain water alone. ^ The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity: 11.6 liters (12.3 US qts, 10.2 Imp. qts) b. Install the radiator cap. c. Bleed the cooling system. 1. Start the engine, and open the heater water valve. 2. Maintain the engine speed at 2,000 - 2,500 rpm, and warm up the engine. d. Stop the engine, and wait until the engine coolant cools down. e. Refill coolant into the reservoir until it is "FULL". 4. CHECK FOR ENGINE COOLANT LEAKS 5. CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY 6. REINSTALL ENGINE UNDER COVER Page 6806 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 5523 B. Pinch the tongue plate stopper into the webbing using an adjustable wrench, and turn and push the adjustment screw by hand. HINT: Press the adjustment screw in order to position the male and female parts of the tongue plate stopper parallel to each other as shown in illustration. CAUTION: DO NOT use pliers. They may damage the webbing. C. When the adjustment screw for the adjustable wrench cannot be turned by hand, tighten the adjustment screw using a pair of adjustable joint pliers until the space between jaws of the adjustable wrench is 4.5 - 5.0 mm. (0.18 in. - 0.20 in. [See illustrations.]) Page 4548 a. Remove the nut and cord clip. b. Remove the 4 screws and rectifier holder. c. Remove the 4 rubber insulators. 5. REMOVE PULLEY a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) b. Check that SST (A) is secured to the rotor shaft. c. Mount SST (C) in a vise. d. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). Locations Anti-Lock Brake System Page 3223 Transmission Mode Indicator - A/T: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 2486 CHART 14 Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Gauge: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 6287 Splice Location B11 Page 1940 CHART 29 Page 3610 8. INSTALL 29 BOLTS TO UPPER VALVE BODY Torque: 6.4 Nm (65 kgf-cm, 4.7 ft. lbs.) HINT: Each bolt length is indicated. Bolt length: Bolt A: 20 mm (0.79 inch) Bolt B: 28 mm (1.10 inch) Bolt C: 40 mm (1.57 inch) 9. INSTALL SOLENOID VALVE a. Install 3 new O-rings to the 3 solenoid valves. b. Install the solenoid valve and lock plate with bolt. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) c. Install the 3 solenoid valves with the 3 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) 10. INSTALL MANUAL VALVE 11. INSTALL PRESSURE RELEASE VALVE Install the spring, ball, spring seat and bolt. Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Page 5141 2. INSTALL SUSPENSION SUPPORT a. Install the cushion, 2 retainers and suspension support to the piston rod. b. Temporarily tighten a new suspension support center nut. c. Position the suspension support as shown in the illustration. d. Remove the SST. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not make your position at the top side of the shock absorber. HINT: After removing the SST, recheck the direction of the suspension support. e. Torque the suspension center nut. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) INSTALLATION 1. INSTALL SHOCK ABSORBER WITH COIL SPRING a. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) b. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 Nm (1,400 kgf-cm, 100 ft. lbs.) 2. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 3080 Mass Air Flow Meter: Testing and Inspection MASS AIR FLOW (MAF) METER INSPECTION 1. DISCONNECT MAF METER CONNECTOR 2. REMOVE MAF METER Remove the 2 screws and MAF meter. 3. INSPECT MAF METER a. Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. b. Inspect for operation. 1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3. Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that the voltage fluctuates. Page 6834 Glossary Of Terms And Symbols (Part 2) Page 4097 9. Remove steering knuckle. A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: Remove grease cap. A. Mount the axle hub in a soft jaw vise. NOTE: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). B. Using a screwdriver, remove the grease cap. NOTE: Be careful not to damage the grease cap. Diagram Information and Instructions Relay Box: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 1873 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Page 4513 Battery: Technical Service Bulletins Battery - Absorbed Glass Mat Battery (AGM) Information SPECIAL SERVICE TOOLS SS006-07 Title: ABSORBED GLASS MAT (AGM) BATTERY INFORMATION Models '01 - '08 Toyota August 11, 2007 Introduction This TSB provides background on the differences and similarities between AGM (Absorbed-electrolyte Glass Mat) batteries and flooded lead acid batteries. It also explains charging procedures performed by the GR8 Battery Diagnostic Station (SST P/N 00002-MCGR8) and its ability to charge AGM batteries at higher current levels then a standard battery charger. Applicable Vehicles ^ 2001 - 2008 model year Toyota vehicles equipped with an AGM battery. Required Tools & Equipment Warranty Information Battery Comparison Differences between AGM and flooded lead acid batteries: ^ AGM batteries have thin, sponge-like, glass mat separators that absorb all liquid electrolytes. ^ Flooded lead acid batteries have free, liquid electrolyte all around the plates and separators. ^ Flooded lead acid batteries can easily release gas that is formed during a charge, while AGM battery life is diminished if gas is formed during charging. Similarities between AGM and flooded lead acid batteries: ^ Both share the exact same lead acid chemistry. Page 6585 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 589 Applicable Vehicles Page 3342 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Page 1742 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Page 6316 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1974 Page 5460 Airbag Sensor Assembly: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. A/T, M/T - Alignment Pin Service Precaution Manual Transmission/Transaxle: Technical Service Bulletins A/T, M/T - Alignment Pin Service Precaution T-SB-0053-08 May 8, 2008 Alignment Pin Installation during Transmission/Transaxle Assembly Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of alignment pins during transmission/transaxle assembly installation. Missing alignment pins may result in incorrect alignment and failure of the transmission/transaxle assembly. Use the information below when installing a transmission/transaxle assembly. Parts Information Warranty Information Repair Procedure 1. Inspect the rear side of the engine block assembly for 2 alignment pins. ^ If there are less than 2 alignment pins present one may have been removed with the transmission/transaxle assembly. Check the removed assembly for the missing alignment pins. Go to step 2. Page 6682 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 815 STANDARD VALUE OF ECU TERMINAL Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST w/ INTERMITTENT If continuity is not as specified, replace the switch. Page 5912 - Length: 6 in. ^ Ratcheting tie down strap (quantity 1) - Minimum Width & Length: 1 in. x 6 ft. ^ Bicycle Cable Lock (quantity 1) - Minimum Width & Length: 3/8 in. x 5 ft. - Built-in lock with key - Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent IV. Background On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame cross-member. In the worst case the spare tire stowed under the truck bed may become separated from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or associated brake lines. Page 1103 Engine Room R/B Details Page 4685 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2280 Page 6259 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3403 Clutch: Specifications O/D Direct Clutch Clutch Drum Bushing Inside Diameter Maximum 27.11 mm O/D Direct Clutch Piston Stroke 1.77 - 2.07 mm O/D Planetary Gear Bushing Maximum 11.27 mm Planetary Pinion Gear Thrust Clearance Standard 0.20 - 0.60 mm Maximum 1.00 mm Flange Thickness No.16 3.6 mm No.17 3.5 mm No.18 3.4 mm No.19 3.3 mm No.20 3.2 mm No.21 3.1 mm Clutch Drum Standard Distance 15.5 - 16.5 mm Piston Return Spring Standard Free Length 15.8 mm Direct Clutch Piston Stroke 1.03 - 1.33 mm Piston Return Spring Standard Free Length 23.25 mm Drum Bushing Inside Diameter 53.99 mm Flange Thickness No.33 3.0 mm No.32 3.1 mm No.31 3.2 mm No.30 3.3 mm No.29 3.4 mm No.28 3.5 mm No.27 3.6 mm No.34 3.7 mm O/D Direct Clutch Speed Sensor x Transmission Case 5.4 Nm Page 735 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Page 1848 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 4991 2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. - If there is slack in the wire harness, the steering wheel pad may come loose due to the shock when the airbag Is deployed. This is highly dangerous. 3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free through the shock from the airbag deploying. - Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. c. Check functioning of the SST. SST 09082-0700 Page 3367 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 5242 Control Assembly: Testing and Inspection Heater Control Assembly On-Vehicle Inspection HEATER CONTROL ASSEMBLY ON-VEHICLE INSPECTION INSPECT HEATER CONTROL DIAL AND LEVER OPERATION Move the control dial and lever left to right and check for stiffness and binding through the full range of the levers. If click sound can not be heard or recoil is felt, adjust the control cable or check control cable and heater control assembly. Component Inspection HEATER CONTROL ASSEMBLY INSPECTION 1. INSPECT BLOWER SPEED CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch and check bulb. 2. INSPECT DEF. MODE SWITCH Page 404 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Electrical Specifications Page 2146 a. Check only the valves indicated. - Using a feeler gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 10. ADJUST VALVE CLEARANCE a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim. d. Determine the replacement adjusting shim size according to these Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T .......................................................................................................................................................... ................. Thickness of removed shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Page 5547 Rear Seat Belt Extender Applications Page 974 Hose/Line HVAC: Testing and Inspection REFRIGERANT LINE ON-VEHICLE INSPECTION 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Page 3977 Steps 1 - 3 Page 4877 1. MEASURE PS VANE PUMP ROTATING TORQUE a. Check that the pump rotates smoothly without abnormal noise. b. Temporarily install the bolt. c. Using a torque wrench, check the pump rotating torque. Rotating torque: 0.28 Nm (2.8 kgf-cm, 2.4 inch lbs.) or less 2. REMOVE SUCTION PORT UNION a. Remove the bolt and suction port union. b. Remove the O-ring from the union. 3. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING a. Remove the pressure port union, flow control valve and spring. b. Remove the O-ring from the pressure port union. 4. REMOVE REAR HOUSING a. Remove the 4 bolts and rear housing. HINT: If the wave washer and side plate are stuck to the rear housing, lightly tap the rear housing with a plastic hammer, and remove the wave washer and side plate. b. Remove the 2 O-rings from the rear housing. 5. REMOVE WAVE WASHER 6. REMOVE SIDE PLATE 7. REMOVE GASKET 8. REMOVE CAM RING, 10 VANE PLATES AND VANE PUMP ROTOR a. Using a screwdriver, remove the snap ring from the vane pump shaft. b. Remove the cam ring, 10 vane plates and vane pump rotor. NOTICE: Be careful not to drop the plate. 9. REMOVE VANE PUMP SHAFT WITH VANE PUMP PULLEY 10. REMOVE STRAIGHT PINS Remove the 2 pins from the front housing. INSPECTION 1. CHECK OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING Using a micrometer and caliper gauge, measure the oil clearance. Standard clearance: 0.03 - 0.05 mm (0.0012 - 0.0020 inch) Maximum clearance: 0.07 mm (0.0028 inch) If it is more than the maximum, replace the shaft and front housing. 2. INSPECT VANE PUMP ROTOR AND VANE PLATES Page 3846 STANDARD VALUE OF ECU TERMINAL Page 6837 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 5512 CAUTION For this procedure, do not use pliers. They may damage the webbing. C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures 5&6 Page 3976 ABS Light: Testing and Inspection CIRCUIT DESCRIPTION If the ECU detects a trouble, the ABS warning light comes on while the ABS control is prohibited and at the same time, the ECU records a DTC in memory. After removing the short pin of the DLC3, connect terminals Tc and CG of the DLC3 to make the ABS warning light blink and to output the DTC. Wiring Diagram Component Locations Audible Warning Device Control Module: Component Locations Instrument Panel Page 1717 DOWNLOAD FILE TO TESTER 2. Download the calibration file to the Diagnostic Tester. The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card. NOTE: Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process. A. Before downloading a new calibration file from TIS, check the current calibration files stored on the Diagnostic Tester Program Card by following the screen flow shown (Figure 4). NOTE: ^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card. ^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown). ^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester software version 10.2a and later. Prior versions may store up to four calibration files. Page 5406 g. Deploy the airbag. 1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. 3. Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. h. Dispose of the steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag Is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Disposing of Steering Wheel Pad With Airbag Deployed DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air-bag 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 steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. Page 6039 Above are items that should be checked periodically and their frequency. Summary Chart for Long-Term Storage A combination of proper Vehicle Receipt, Pre-Delivery Service and Vehicle Storage is the only way to maintain factory fresh vehicles. Toyota's goal is to deliver 100% problem-free cars and trucks. With your commitment to quality and customer satisfaction, we can reach that goal. Review this TSB often and be sure new employees are aware of the policies and procedures out-lined herein, as individual training in proper inspection, pre-delivery service, and storage and handling techniques are essential to ensure high delivery quality. Here is a list of additional resources, which will help you with vehicle receipt, inspection and storage procedures. Reference and Training Materials ^ CRIB # 165, Acid Rain Paint Finish Damage - Prevention and Repair ^ UoT e-Learning Course E257 Vehicle Delivery Quality - Paint Finish Repair ^ Dealer Delivery Quality Operations Guide, P/N 00116-DDQ0G-98 ^ BO020-91, Prevention and Repair of Acid Rain Damage ^ BO05-04, New Vehicle Washing Schedule for Paint Protection ^ PG001-06, Battery Maintenance for In Stock Vehicle and Pre-Delivery ^ PA005-04, Iron Particle Rust Contamination Repair ^ PG005-94, Rapgard(TM) Removal Procedures ^ PG007-02, Wheel Film for Brake Rotor Rust Prevention ^ Maintenance for HV & Auxiliary Batteries, Refer to applicable HV models. Page 4052 A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. SST P/N: 09950-60020 (09951-00810) SST P/N: 09950-70010 (09951-07150) 16. Install new bearing. A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. SST P/N: 09527-17011 SST P/N: 09950-60020 (09951-00910) B. Using snap ring pliers, install a NEW snap ring. 17. Install new oil seal (outside). A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). SST P/N: 09223-15030 Page 2865 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 5907 Page 3330 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: A/T - Fluid Requirements Fluid - CVT: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information Page 6757 Engine Room R/B Page 2412 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 628 CHART 22 Page 999 Fluid - A/T: Service and Repair 1. Drain transaxle fluid, then install drain plug and new gasket. 2. With engine Off, add fluid through dipstick tube. Do not overfill. 3. Start engine, then move shift selector through all positions, ensuring smooth operation. 4. Allow to idle, then check at COOL level. 5. Allow to reach normal operating temperature, then recheck. Page 4077 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Repair Procedure Page 424 Key Reminder Switch: Pinout Values and Diagnostic Parameters KEY REMINDER AND SEAT BELT WARNING B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Page 6946 INSPECT PASSENGER'S DOOR POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT POWER WINDOW MASTER SWITCH CIRCUIT Disconnect the connector from the master switch and inspect the connector on the wire harness side. * Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver or a passenger's door is opened after the ignition switch is turned ON to OFF (ACC). If the circuit is not as specified, inspect the circuits connected to other parts. Page 5933 Information PRELIMINARY INSPECTION INSTRUCTIONS Page 487 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 8. REINSTALL INTAKE AIR CONNECTOR 9. REFILL WITH ENGINE COOLANT 10. REINSTALL THROTTLE BODY COVER Page 5995 Headliner: Service and Repair REMOVAL HINT: Tape the screwdriver tip before using it to remove the parts. 1. Access cab: REMOVE REAR SEAT 2. REMOVE FRONT DOOR SCUFF PLATES a. Standard cab: Remove the 10 screws and front door scuff plates. b. Access cab: Remove the 8 screws and front door scuff plates. 3. Access cab: REMOVE ACCESS DOOR SCUFF PLATES Remove the 6 screws and access door scuff plates. 4. Access cab: REMOVE FRONT DOOR REAR SCUFF PLATES a. Remove the 2 clips and 2 covers. b. Remove the 2 clips and 2 front door rear scuff plates. 5. REMOVE ASSIST GRIPS a. Using a screwdriver, remove the caps. b. Driver's side: Using a torx driver, remove the 2 torx screws and assist grip c. Passenger's side: Using a torx driver, remove the 4 torx screws and 2 assist grips. 6. REMOVE FRONT PILLAR GARNISH a. Using a screwdriver, remove the front pillar garnish. b. Employ the same manner described above to the other side. 7. Access cab: REMOVE FRONT SEAT OUTER BELT ANCHORS Locations Instrument Panel Page 1991 CHART 21 Page 734 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Testing and Inspection Air Bag Deactivation Indicator: Testing and Inspection INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 2482 CHART 8 CHART 9 Page 6616 Key Reminder Switch: Pinout Values and Diagnostic Parameters KEY REMINDER AND SEAT BELT WARNING B7 (A), (B) BUCKLE SW LH (A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use D16 DOOR COURTESY SW FRONT LH 1 - GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1 - 2 : Closed with ignition key in cylinder C11 (A), C12 (B), C13 (C) COMBINATION METER (A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND : Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open (Access cab) (C) 1 - GROUND : Continuity with the ignition key in cylinder (B) 9 - GROUND : Continuity with the driver's seat belt in use (B) 5 - GROUND : Always approx. 12 volts (A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position Description and Operation Brake Signal: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle 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 operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 4711 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Diagrams Locations Intake Air Temperature Sensor: Locations Mass Air Flow (MAF) Meter The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 1583 3. ASSEMBLE SST SST 09230-01010, 09231-14010 a. Install the punch assembly 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" shown in the diagram. Dimension "B": 8.4 mm (0.34 inch) 4. CAULK LOCK PLATE a. 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 squeezing the handle until stopped by the stopper bolt. SST 09230-01010 HINT: ^ Do not stake the areas protruding around the ports and flanges. Page 4317 ^ 09023-00100 6. REMOVE BRAKE CALIPER AND DISC A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. Page 1715 Materials System. Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Process Overview ECU Flash Reprogramming is a 4-step process: 1. Locate the desired calibration file on TIS (Technical Information System). Calibration files may be found in two areas: a. Search by model and year for a Technical Service Bulletin addressing a specific product issue. b. Search by model under the ECU Flash Reprogramming section. 2. Download the calibration file from TIS to the Diagnostic Tester. The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card. 3. Reprogram the vehicle ECU with the Diagnostic Tester. Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming. 4. Confirm successful flash update and affix calibration update sticker. Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker. NOTE: Page 6165 Sound Proofing / Insulation: Description and Operation Low Vibration, Low Noise Body Description An effective application of vibration damping and noise supressant materials reduces engine and road noise. Sound Absorbing and Vibration Damping Materials ^ In conjunction with the use of a asphalt sheet which decreases the noise level, asphalt sheet is applied to most of the floor area to reduce engine and road noise during vehicle operation. ^ Foamed material is provided inside the piller; rockers and doors. As a result, the wind noise and road noise that are transmitted to the rockers and the pillers have been reduced. Page 4367 ^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) Specifications Fluid Pump: Specifications Body Clearance Standard 0.07 - 0.15 mm Maximum 0.3 mm Tip Clearance Standard 0.11 - 0.14 mm Maximum 0.3 mm Side Clearance Standard 0.02 - 0.05 mm Maximum 0.1 mm Pump Body Bushing Inside Diameter Maximum 38.19 mm Stator Shaft Bushing Inside Diameter Front SIde Maximum 21.58 mm Rear Side Maximum 27.08 mm Stator Shaft x Oil Pump Body 10 Nm Oil Pump x Transmission Case 22 Nm Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1112 Glossary Of Terms And Symbols (Part 1) Page 6600 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3110 Throttle Position Sensor: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE THROTTLE BODY COVER 2. INSPECT SYSTEM OPERATION a. Check that the throttle linkage moves smoothly. b. Inspect the throttle control motor for operating sound. 1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3. When turning the accelerator pedal position sensor lever to the full-open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring and ECM. Page 2200 Page 3756 Transmission Mode Indicator - A/T: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3910 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1754 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 1861 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 2815 CHART 11 Page 2148 Exhaust: N = T + (A - 0.30 mm (0.012 inch)) 3. Select a new shim with thickness as close as possible to the calculated value. HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787 inch) to 2.80 mm (0.1102 inch). e. Place a new adjusting shim on the valve. f. Place the valve lifter. A/C - Insufficient Cabin Cooling Heater Control Valve: Customer Interest A/C - Insufficient Cabin Cooling HEATING & AIR CONDITIONING AC004-04 May 20, 2004 Title: POOR PERFORMANCE OF A/C SYSTEM Models: '01 - '04 Sequoia & '00 - '04 Tundra May 20, 2004 Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to correct the condition. Applicable ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change Effective VINs shown below. ^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 6007 Component Inspection Evaporator Case: Testing and Inspection Component Inspection INSPECTION 1. CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air. 2. CHECK FITTING FOR CRACKS FOR SCRATCHES If necessary repair or replace. 3. INSPECT THERMISTOR RESISTANCE a. Place the thermistor in cold water and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. b. Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. Page 4351 11. 4WD: Remove oil seal (inside). A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration above). B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. Remove axle hub from steering knuckle. A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. SST P/N: 09710-28012-01 (09710-07031) SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. Remove bearing from steering knuckle. Page 5738 Radio And Player Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 4781 Glossary Of Terms And Symbols (Part 2) Page 2391 Applicable Vehicles Page 633 CHART 25 Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair ON-VEHICLE REPAIR 1. 5VZ-FE: DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission. 2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 4. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR NOTICE: Be careful not to twist the wire harness. 6. CONNECT OIL COOLER PIPE a. Install the elbow to the transmission. Fuel System - Fuel Injector Cleaning Procedure Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Cleaning Procedure PRODUCT GENERAL INFORMATION PG011-05 REVISED October 13, 2005 Title: FUEL INJECTOR CLEANING Models: '90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection TSB REVISION NOTICE: ^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device and Toyota Adaptor Pak), and the note with ordering information has been updated. Previous versions of this TSB should be discarded. Introduction Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogged or blocked fuel injectors. The following procedure has been developed to clean the fuel injectors. Applicable Vehicles: ^ All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI). Required Tools & Material Warranty Information Repair Procedure 1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, complete the fuel injector power flush using the following instructions: A. Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): ^ Idle air control device ^ Throttle plate (both sides if possible) ^ Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. Page 5128 Suspension Spring ( Coil / Leaf ): Service and Repair REMOVAL 1. SUPPORT BODY WITH SAFETY STANDS a. Jack up and support the body on safety stands. b. Lower the axle housing until the leaf spring tension is free, and keep it at this position. 2. REMOVE REAR WHEEL Instruments - Oil Pressure Gauge Reads Abnormally Low Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low ELECTRICAL EL017-03 December 23, 2503 Title OIL PRESSURE GAUGE READS LOW Models '01 - '04 Sequoia & '00 - '02 Tundra TSB UPDATE NOTICE: This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded. Introduction Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads abnormally low at idle. An updated oil pressure sender has been created to address this condition. Applicable Vehicles ^ 2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective VINs shown below. ^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Repair Procedure 1. Replace the Oil Pressure Sender. 2. Verify proper operation of the Oil Pressure Gauge. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 2364 Step 1 Page 3513 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Specifications Exhaust Manifold: Specifications Maximum Warpage 0.50 mm RH Exhaust Manifold W/ Nuts 44 Nm LH Exhaust Manifold W/ Nuts 44 Nm Page 376 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. - At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install them to the switch. INSTALLATION Installation is in the reverse order of removal. Page 5873 2. If reusing the moulding: CLEAN MOULDING a. Using a heat light, heat the moulding to 20 - 30 °C (68 - 86 °F). NOTE: Do not heat the body excessively. b. Remove the adhesive tape from the moulding. c. Wipe off stains with cleaner. d. Apply a new adhesive tape to the moulding as shown in the illustration. 3. INSTALL MOULDING a. Using a heat light, heat the body and moulding. Body : 40 - 60 °C (104 - 140 °F) Moulding : 20 - 30 °C (68 - 86 °F) NOTE: Do not heat the moulding excessively. b. Lift the moulding release sheet from face of the moulding. NOTE: When the moulding release sheet is removed, make sure that no dirt or dust can get onto the uncoated area. c. Align the bosses with their corresponding holes in the body, and press firmly on the moulding. NOTE: Do not apply excessive force onto the moulding, but steady pressure with your thumbs. Page 2456 Engine Bank Identification Page 466 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Page 6217 Problem Symptom Confirmation (Road Test) PROBLEM SYMPTOM CONFIRMATION (Road Test) Engine Controls - O2 Sensor Monitor Threshold Values Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 5814 Trailer Towing Page 5094 Page 5446 Wiring Diagram Page 1090 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.1 Page 2090 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 19 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 3669 11. REPLACE BEARING CASE a. Remove the outer side oil seal (See step 5.). b. Remove the bearing (See step 6.). c. Remove the serration bolts (See step 1.). d. Remove the bearing case. e. Position the backing plate on a new bearing case and using 2 socket wrenches and a press, install the serration bolts. f. Install a new bearing (See step 6.). g. Install a new outer side oil seal (See step 7.). 12. REPLACE OIL DEFLECTOR a. Using a brass bar and hammer, remove the hub bolts, oil deflector and gasket. b. Position a new gasket and oil deflector on the axle shaft and install a washer and nut to the hub bolt and install the hub bolt by torquing the nut. c. Remove the nut and washer. 13. INSTALL REAR AXLE SHAFT IN BACKING PLATE a. Coat the new outer side oil seal lip with MP grease. b. Install the backing plate and bearing retainer on the rear axle shaft. c. Using SST and a press, install the rear axle shaft into the backing plate. SST 09316-60011 (09316-00051) d. Using snap ring expander, install a new snap ring. 14. w/ ABS: INSTALL ABS SPEED SENSOR ROTOR AND BEARING RETAINER (DIFFERENTIAL SIDE) Using SST and a press, install a new sensor rotor and new bearing retainer to the axle shaft. SST 09316-60011 (09316-00051) Standard length: 122.2 ± 1.0 mm (4.811 ± 0.039 inch) Page 3371 NOTE On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes. Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL and do not require troubleshooting. They will clear during normal driving once the Universal Trip Drive Pattern is performed. 4. Attach the Authorized Modifications Label. A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. B. Attach the label under the hood in the location determined by the specific TSB or Campaign. NOTE Wait 60 - 90 seconds for ink to set before handling. Page 1767 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 5628 a. Check the functioning of SST. CAUTION: When activating the seat belt pretensioner, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700,09082-00740 1. Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the seat belt pretensioner. 2. Press the SST activation switch, and check the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. b. Standard cab: Disconnect the pretensioner connector. 1. Remove the front door scuff plate. 2. Remove the front pillar garnish. 3. Remove the back panel upper garnish. 4. Remove the front seat outer belt floor anchor. 5. Remove the quarter trim. Page 5595 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 6854 Daytime Running Lamp Relay: Testing and Inspection Terminal Identification Connector Disconnected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Connector Connected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Connect the wire harness side connector to the relay and inspect wire harness side connector from the back side, as shown. If circuit is not as specified, try replacing the relay with a new one. Page 6477 Steps 1 - 2 Page 2616 J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process. K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND. Page 6602 Glossary Of Terms And Symbols (Part 2) Page 66 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 1781 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 1976 O2S Application Table O2S Failure Threshold Charts Page 6722 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2077 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. Page 210 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 3883 Step 3 Page 1972 Page 1553 4. Cycle the temperature control knob several times and confirm proper water control valve adjustment. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 5617 Seat Belt Reminder Lamp: Testing and Inspection INSPECT DRIVER'S SEAT BELT WARNING LIGHT a. Disconnect the connector B from the combination meter. b. Connect the negative (-) lead from the battery to terminal 9. c. Turn the ignition switch ON and check that the warning light lights UP. If the warning light does not light up, inspect the bulb or wire harness. INSPECT PASSENGER SEAT BELT WARNING LIGHT a. Remove the center cluster finish panel. b. Disconnect the connectors from the center cluster integration. c. Connect the positive (+) lead from the battery to the terminal 4 and negative (-) lead terminal 16, and check that the warning light lights UP. If the warning light does not light up, inspect the bulb or wire harness Page 4281 3. BLEED BRAKE LINE (a) Connect the vinyl tube to the caliper. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. SST 09751-36011 (c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (d) Repeat (b) and (c) until all the air in the fluid has been bled out. Torque: (Bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.) (e) Repeat the procedure on the previous page to bleed the air out of brake line for each wheel. 4. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 LOAD SENSING PROPORTIONING AND BY-PASS VALVE ON-VEHICLE INSPECTION 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab: 5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.) 2. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi) Page 4381 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. ^ 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. ^ 09710-28012-01 (09710-07031) ^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. Page 4623 Engine Room R/B Details Page 3468 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 5955 Page 1234 e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time. 4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away. 5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag. g. Observe these precautions when connecting the fuel tube connector (quick type): 1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe. Page 4596 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 6092 Page 679 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 178 C. Choose desired ECU group(s) in the Health Check dialog box. D. Click Next. E. Click Continue to view Health Check results. F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS. NOTE ^ Note any DTCs stored in Systems that will be flash reprogrammed. ^ Clicking the link will automatically launch TIS and perform a calibration search. G. Log in to TIS. (If already logged in skip this step.) H. To review the TSB and access the calibration file click the service bulletin link in the Document Title column of the Calibration Search Result portlet. Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Terminals Of ECM - Connector View Terminals Of ECU - Connector Pinouts (Part 1) Page 2080 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Page 6081 Paint: Technical Service Bulletins Vehicle - Long Term Storage Guidelines T-SB-0079-09 Rev1 March 4, 2009 Long Term Vehicle Storage Guidelines Service Category General Section Maintenance Market USA Applicability December 23, 2009 Rev1: TSB REVISION NOTICE ^ Applicability has been updated to include 2010 Prius PHV model and 2011 vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Long-term or off-site storage requires special care to keep vehicles factory fresh and ready for delivery. The following guidelines should be performed to minimize vehicle component/part degradation due to extended vehicle storage conditions. Long-term storage can affect a vehicle's systems and components. Any problems that are found should be corrected immediately. Required Tools & Equipment Warranty Information Procedure Page 5107 Page 5029 6. DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM a. Remove the cotter pin and nut. b. Using SST, disconnect the lower ball joint from the lower suspension arm. SST 09628-62011 7. REMOVE LOWER SUSPENSION ARM a. Place matchmarks on the front and rear cam plates and chassis frame. b. Remove the 2 cam plates, bolts, cams and lower suspension arm while slightly shifting the power steering gear rearward. NOTICE: Do not damage the power steering gear tubes. REPLACEMENT 1. REPLACE BUSHING a. Using a chisel and hammer, pry up the flange of the bushing. b. Using SST and a press, remove the bushing. SST 09613-26010, 09632-36010, 09950-00020 c. Using SST, a press and steel plate, install a new No.1 bushing. SST 09502-12010, 09631-12090 HINT: Before installing the bushing, set it in the correct direction, as shown in the illustration. Page 2644 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 2550 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 4382 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 Page 134 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 4270 Brake Shoe: Specifications Brake Shoe Lining Thickness Standard Thickness 6 mm Minimum Thickness 1 mm Shoe Clearence 0.5 mm Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY a. remove the reservoir tank cap and strainer. b. Disconnect the connector. c. Check that no continuity exists between the terminals with the switch OFF (float up). d. Use siphon, etc. to take fluid out of the reservoir tank. e. Check that continuity exists between the terminals with the switch ON (float down) f. Pour the fluid back in the reservoir tank. If operation is not as specified, replace switch. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 6372 - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 6659 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 4173 SST P/N: 09527-17011 B. Coat MP grease to the oil seal lip. 18. Install new dust cover and axle hub to steering knuckle. A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. SST P/N: 09649-17010 19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is installed completely. 20. 2WD: Install new lock nut. A. Using the following SST, install and torque a NEW lock nut to the axle hub. SST P/N: 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. Page 4806 Glossary Of Terms And Symbols (Part 2) Page 5417 Impact Sensor: Description and Operation FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled. Page 6879 Lamp Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Paint - Gray Bumper Paint Colors Paint: Technical Service Bulletins Paint - Gray Bumper Paint Colors PAINT PA001-03 January 23, 2003 Title 1995-2003 GRAY BUMPER PAINT CODES Models '95- '03 Tacoma & '00 - '03 Tundra Introduction Following are color codes for gray painted steel bumpers installed on the 1995 - 2003 model year Tacoma and 2000 - 2003 model year Tundra. These bumpers are factory installed usually on base trim level models. Applicable Vehicles ^ 1995 - 2003 model year Tacoma vehicles. ^ 2000 - 2003 model year Tundra vehicles. Parts Information Warranty Information Page 2731 Page 6160 b. Inspect the connector on the wire harness side. If circuit is not as specified, inspect the circuits connected to other parts. Page 975 Hose/Line HVAC: Service and Repair REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system 3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TORQUE NOTE: Connections should not be torqued tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT AIR CONDITIONING OPERATION Page 695 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Page 2890 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Page 6198 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 4063 Repair Procedure 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer, remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. Page 2591 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Electrical Specifications Resistance Electrical - SRS And HV Wiring Repairs Battery System, Hybrid Drive: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 203 B. You have the option to delete calibrations off the tester before downloading a new calibration. The CUW also provides this option if there is not enough memory for the new calibration. To delete one or all of the calibrations, follow the screen flow shown (Figure 5). C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in Figure 6. This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary, select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to install or reinstall CUW. Page 5487 Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film about 5 mm for each side. (Not fully released.) B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Match the shoulder belt anchor to the center of the tape. C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. NOTE: ^ Be sure to affix the fluorocarbon tape securely along all edges. ^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape. E. Remove the clip. F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocarbon resin tape and confirm the smoothness of the belt movement. Page 2822 Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for no more than 5 - 10 seconds at a time. If the spark does not occur, do the test as per the given flow chart. 7. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) 8. Reinstall the ignition coils (with igniter). Page 2691 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Page 4335 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) B. Using Snap ring pliers, install a NEW snap ring. 17. INSTALL NEW OIL SEAL (OUTSIDE) A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside). ^ 09223-15030 Diagrams Removal And Installation Evaporator Case: Service and Repair Removal And Installation Cooling Unit REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Page 847 a. Loosen the front and/or rear adjusting cam set bolts. b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. c. How to read adjustment chart (Example). 1. Find the applicable wheel alignment standard value for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10'(0.17°) Caster: 3°00' 3. Measure the present wheel alignment value with the vehicle in non-loaded condition. 4. Mark the measured present value on the adjustment chart. Example: Camber: 0°30'(0.50°) Caster: 2°40'(2.67°) Page 3764 Electronically Controlled Transmission And A/T Indicator (Part 2) Page 1606 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Page 4091 Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 4631 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2349 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 5265 NOTE: - Do not use tools like screwdriver to remove the tube. - Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tubes. - After connection, check the fitting for claw of the piping clamp. 3. DISCONNECT SUCTION TUBE FROM COOLING UNIT FITTINGS Loosen the nut and disconnect both the tube. Torque: 32 N.m (330 kgf.cm, 24 ft.lbf) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate a new O-ring with compressor oil and install them to the tube. 4. REMOVE GLOVE COMPARTMENT PARTS 5. REMOVE LOWER NO.2 FINISH PANEL 6. REMOVE LOWER CENTER COVER 7. REMOVE LOWER LH FINISH PANEL 8. REMOVE LOWER COVER Page 1997 CHART 25 Page 4148 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS Using a screwdriver, remove the 4 cylinder boot set rings and boots. 2. REMOVE PISTONS FROM CYLINDER (a) Prepare the wooden plate to hold the pistons. Page 2960 4. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply small amount of fresh engine oil on the tip of the pipe. 5. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. 6. Check if there is any fuel leakage. h. Observe these precautions when handling nylon tube. 1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by bending it. i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 4130 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. ^ 09023-00100 6. REMOVE BRAKE,CALIPER AND DISC Page 3637 Fluid - Differential: Fluid Type Specifications Differential Fluid Front Grade ......................................................................................................................................... .............................................................. GL-5 or equivalent Viscosity ................................................. .......................................................................................................................................................... SAE 75W-90 Rear Grade .................................................................................................................... ................................................................................... GL-5 or equivalent Above -18° C (0° F) .......... .............................................................................................................................................................. ........................... SAE 90 Below -18° C (0° F) .................................................................................... ......................................................................................... SAE 85W-90 or 80W Page 5731 Radio/Stereo: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 546 Page 2217 Data Link Connector: Description and Operation 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. Page 1272 A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the accessory drive belt tensioner to release tension and remove the accessory drive belt. HINT: The pulley bolt for the belt tensioner has a left hand thread. B. Using the accessory drive belt routing label located on the passenger side of the radiator core support as a guide, install the new accessory drive belt. 2. Check belt tensioner operation. A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force. B. Ensure proper alignment of the belt with the ribbed grooves of each pulley. C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each pulley. D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see illustration). E. If the arrow mark falls outside area "A," the drive belt is incorrect. HINT: When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect. Page 2693 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position sensor. INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR a. Install the crankshaft position sensor with the bolt. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) b. Connect the crankshaft position sensor connector. 2. INSTALL ENGINE UNDER COVER Page 5179 Wheel Bearing: Tools and Equipment Wheel Bearing Nut Socket AST tool# TOY 185 Page 2759 CHART 14 Page 5967 Page 3998 REMOVAL 1. REMOVE BRAKE LINE COVER 2. DISCONNECT CONNECTOR Pull out the release bar, and disconnect the connector. 3. DISCONNECT BRAKE LINES Using SST, disconnect the 5 brake lines from the ABS actuator. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 4. REMOVE ABS ACTUATOR ASSEMBLY Remove the 3 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.) 5. REMOVE ABS ACTUATOR (a) Remove the 3 nuts and ABS actuator from the actuator bracket. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) (b) Remove the 3 holders and 3 cushions from the ABS actuator. INSTALLATION Page 5057 Page 4659 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 4881 6. INSTALL VANE PLATES AND GASKET a. Install the 10 plates with the round end facing outward. b. Install a new gasket on the front housing. NOTICE: Be careful of the direction of the gasket. 7. INSTALL SIDE PLATE Align the holes of the plate and 2 straight pins. 8. INSTALL WAVE WASHER Install the washer so that its protrusions fit into the slots in the side plate. 9. INSTALL REAR HOUSING a. Coat 2 new O-rings with power steering fluid and install them to the rear housing. b. Install the rear housing with the 4 bolts. Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.) 10. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION a. Install the spring to the front housing. b. Install the flow control valve facing the correct direction. c. Coat a new O-ring with power steering fluid and install it to the pressure port union. d. Install the pressure port union. Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.) 11. INSTALL 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. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) 12. MEASURE PS VANE PUMP ROTATING TORQUE Testing and Inspection Windshield Washer Spray Nozzle: Testing and Inspection INSPECTION 1. INSPECT WASHER NOZZLE a. While operating the washer, check whether the upper point where the washer fluid hits the windshield and the surge area are within the range indicated by the hatched line. b. Check if the lower point where the washer fluid hits the windshield is within the range of the wiping pattern (the area of the glass which is wiped by the wiper blades). 2. ADJUST WASHER NOZZLE Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield. Page 3793 Steps 1 - 2 Page 3465 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Removal and Installation Compressor Clutch: Service and Repair Removal and Installation COMPRESSOR AND MAGNETIC CLUTCH Compressor And Magnetic Clutch (Part 1) Page 2961 5. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3. Page 1738 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Page 1911 Page 2474 Page 2994 D. Start the engine. After the engine has stalled, turn the ignition switch OFF. E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable. NOTE: Do NOT clamp plastic lines. F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose. G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter. H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls. I. Turn the ball valve OFF and remove the empty can. J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system. K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector. L. Before starting the vehicle, pressurize the fuel system and check for leaks. Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system. 2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N 08813-0080DS) to the fuel tank. 3. Road test the vehicle to verify normal operation. Page 4207 Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 25. Install shock absorber with coil spring. A. Install the upper side of shock absorber to the chassis frame with the 3 nuts. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts. A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) NOTE: It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. B. Install the disc, brake caliper, and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. Install new brake line. Using the SST, connect NEW brake line. SST P/N: 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. With ABS: Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: Install drive shaft lock nut. A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: Install grease cap. 31. Install front wheel. NOTE: Do NOT use an air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) Page 2831 CHART 26 Page 4560 Starter (Part 2) Page 4131 A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. 8. DISCONNECT LOWER BALL JOINT Testing and Inspection Four Wheel Drive Selector Switch: Testing and Inspection INSPECTION 1. INSPECT 2WD -> 4HI SHIFT a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4 switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4 switch is in OFF position. HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be moved back and forth. - If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash. 2. INSPECT 4HI -> 4LO SHIFT Page 2503 Page 1924 CHART 18 CHART 19 Page 2447 CHART 29 Restraints - OCS System Initialization Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 837 Alignment: Specifications Page 1643 4. REMOVE WATER INLET AND INLET HOUSING ASSEMBLY a. Disconnect the water bypass hose from the water inlet housing. b. Remove the 2 bolts holding the water inlet housing to the water pump. c. Disconnect the water inlet housing from the front water bypass joint, and remove the water inlet and inlet housing assembly. d. Remove the O-ring from the water inlet housing. 5. REMOVE WATER PUMP a. Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. b. Remove the O-ring from the water bypass pipe. INSPECTION 1. INSPECT WATER PUMP a. Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump and timing belt. b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING a. Remove the 4 nuts and fan from the fluid coupling. Page 2724 Engine Bank Identification Page 4909 Key Reminder Switch: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 1727 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Page 4206 21. 4WD: Using the following SSTs and a press, install the bearing spacer. SST P/N: 09950-60010 (09951-00650) SST P/N: 09950-70010 (09951-07150) 22. 4WD: Install new oil seal (inside). A. Using the following SST and a plastic hammer, install a NEW oil seal (inside). SST P/N: 09527-17011 NOTE: Lightly strike the SST on its circumference evenly. B. Coat MP grease to the oil seal lip. 23. Install steering knuckle. A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut. NOTE: Be careful not to damage the oil seal and drive shaft boot. B. Connect the steering knuckle to the upper suspension arm. C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf) 24. Connect the lower ball joint to the steering knuckle with 4 bolts. Page 350 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3334 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 2833 CHART 27 Page 3102 b. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) c. Install the ventilation cap. d. Connect the water bypass hose and PCV hose to the throttle body. e. Connect the throttle position sensor connector. f. Connect the throttle control motor connector. g. Connect the accelerator pedal position sensor connector. h. Connect the accelerator pedal position sensor wire to the 2 clamps on wire brackets. 2. CONNECT ACCELERATOR CABLE TO THROTTLE BODY 3. INSTALL INTAKE AIR CONNECTOR 4. FILL WITH ENGINE COOLANT 5. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 6. INSTALL THROTTLE BODY COVER Page 1905 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Testing and Inspection Interior Light Switch: Testing and Inspection INSPECT FRONT PERSONAL LIGHT SWITCH CONTINUITY a. Disconnect the connector from the personal light. b. Push the personal light switch ON, check that continuity exists between terminal 3 and body terminal 1. c. Turn the light switch to DOOR, check that continuity exists between terminal 2 and 3. If operation is as specified, replace the switch. INSPECT ROOM LIGHT SWITCH a. Disconnect the connector from the interior light assembly. b. Turn the interior light switch ON, check that continuity exists terminal 2 and body ground. c. Turn the interior light switch to DOOR, check that continuity exists between terminals 1 and 2. If operation is not as specified, replace the switch. Page 5882 1. REMOVE REAR BODY SIDE PANEL PROTECTOR Using a moulding remover, remove the 2 protectors. NOTE: The protector has 21 clips as shown in the Illustration. - Be careful not to damage the clips. 2. REMOVE TAIL GATE PROTECTOR a. Remove the 6 pins. b. Using a clip remover, remove the protector and 10 clips. INSTALLATION Installation is in the reverse order of removal procedure. Page 5625 Seat Belt Tensioner: Testing and Inspection Replacement Requirements REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking item functioning of SST. - If the front seat outer belt has been dropped. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. Page 2487 CHART 15 Page 3816 a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4 switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and the 4HI indicator lights come on when the touch select high-low switch is in OFF position. HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position. - If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash. 3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals. Touch select 2-4 switch Touch select high-low switch: If continuity is not as specified, replace the center integration panel assembly. 4. INSPECT ACTUATOR RESISTANCE a. Using an ohmmeter, measure the resistance between terminals 1 and 2. Standard resistance: 0.3 - 100 Ohms b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground. Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the actuator assembly. Page 3245 Electronically Controlled Transmission And A/T Indicator (Part 3) Page 58 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 212 B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19. NOTE: ^ Each flash calibration update will take approximately 15 to 45 minutes. ^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number). ^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU. ^ Failure to complete all updates may result in PERMANENT ECU DAMAGE! CONFIRM UPDATE 4. Confirm successful flash calibration update and affix calibration update sticker. Follow these steps to confirm the calibration was reprogrammed to the ECU. Specifications Page 733 Step 1 Page 3573 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 1556 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. Page 5793 Splice Location B11 Page 3156 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Brakes - Front Brake Caliper Identification Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification BRAKES BR001-03 REVISED January 8, 2003 Title: FRONT BRAKE COMPONENT IDENTIFICATION Models: '00 - '05 Tundra, '01 - '05 Sequoia TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now obsolete and should be discarded. TSB REVISION NOTICE: March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note" added. The previous TSB should be discarded. Introduction There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are intended to assist you in identifying and ordering the correct replacement pads and fitting kits. Applicable Vehicles: ^ 2000 - 2005 model year Tundra vehicles. ^ 2001 - 2005 model year Sequoia vehicles. Warranty Information Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 4103 32. Depress brake pedal several times. 33. Fill the brake reservoir with brake fluid and bleed brake system. 34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS): 2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check). Repair Procedure No. 2 1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits. NOTE: It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform rotor run out. DO NOT turn the rotor using an off-the-car brake lathe. 2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on the rotor), replace the rotors using the service parts from the Parts Information table. 3. Check any new disc rotor for runout. 4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure. 5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts Information table. 6. Perform a road test. Testing and Inspection Hazard Warning Switch: Testing and Inspection INSPECT HAZARD WARNING SWITCH CONTINUITY a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster integration. c. Check that continuity exists between terminal 17 and terminal 1 with the switch ON. d. Check that no continuity exists between terminal 17 and terminal 1 with the switch OFF. If continuity is not as specified, replace the switch. Page 2577 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 21 Audible Warning Device Control Module: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Service and Repair Fuel Pressure Release: Service and Repair SFI SYSTEM PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector. b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. Page 4662 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4566 Using vernier calipers, measure the brush length. Standard length Minimum length If the length is less than minimum, replace the brush holder and field frame. 11. INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load Minimum spring installed load If the installed load is less than minimum, replace the brush springs. Page 3492 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Page 464 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Description and Operation Braking Sensor/Switch: Description and Operation Stop Light Switch This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. Page 209 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 3967 STANDARD VALUE OF ECU TERMINAL Page 185 Then click Start. I. Do NOT disturb the vehicle during flash reprogramming. NOTE ^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file. ^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes). NOTE ^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. ^ If vehicle requires a SECOND calibration update, then continue as follows: ^ For serial communication vehicles, go to step J. ^ For CAN communication vehicles, go to step L. ABS/TCS - Zero Point Calibration Information Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2987 e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check that there is any dirt or the like on the pipe and around the connector before disconnecting them and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at this time. 4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it away. 5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects by covering them with a vinyl bag. g. Observe these precautions when connecting the fuel tube connector (quick type): 1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe. Page 5513 D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female part and is firmly held to the belt webbing. Page 2275 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 193 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 102 Driver Side J/B And Integration Relay Page 5605 Glossary Of Terms And Symbols (Part 1) Page 3078 Mass Air Flow (MAF) Meter Page 2256 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 4301 SST P/N: 09527-17011 B. Coat MP grease to the oil seal lip. 18. Install new dust cover and axle hub to steering knuckle. A. Install the NEW dust cover to the steering knuckle with the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) B. Using the following SST and a press, install the axle hub to the steering knuckle. SST P/N: 09649-17010 19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is installed completely. 20. 2WD: Install new lock nut. A. Using the following SST, install and torque a NEW lock nut to the axle hub. SST P/N: 00002-00909 (09318-12010) Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) NOTE: Do NOT use air wrench. B. Using a chisel and hammer, stake the lock nut. Page 5944 Page 2457 A/F and 02 Sensor Identification Page 4778 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2568 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 1837 Camshaft Position Sensor Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 2002 Page 1710 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 3763 Transmission Mode Indicator - A/T: Electrical Diagrams Electronically Controlled Transmission And A/T Indicator (Part 1) Page 1986 CHART 15 Page 3309 ^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. ^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE ^ Calibration files are embedded as live links in the service bulletin. ^ Some vehicles require special preparation - please review the selected TSB carefully. B. Click Open to load calibration file information. Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. NOTICE Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical Page 1769 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 6725 Brake Lamp: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3707 3. Rear propeller shaft: INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns freely. If the bearing is damaged, worn, or does not turn freely, replace it. 4. Rear propeller shaft: INSPECT WITH DOUBLE CARDAN JOINT PROPELLER SHAFT a. Inspect the shaft for wear or damage. b. Inspect the double cardan joint for wear or damage. If any problem is found, replace the propeller shaft assembly. HINT: Double cardan joint is used on rear propeller shaft. REASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. HINT: When removing or installing any part, make sure that each joint is facing to the correct direction. 1. Rear propeller shaft: INSTALL CENTER SUPPORT BEARING ON INTERMEDIATE SHAFT HINT: Install the center support bearing in the direction. 2. Rear propeller shaft: INSTALL FLANGE ON INTERMEDIATE SHAFT a. Coat the splines of the intermediate shaft with MP grease. Page 6176 Tail Gate Electrical Specifications Resistance Page 4201 A. Disconnect shock absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the 8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint. Specifications Axle Nut: Specifications Front Drive Shaft Lock Nut 235 Nm (173 ft.lb) Page 673 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 529 Page 2279 ^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.") ^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming. ^ Set the parking brake. ^ Complete ALL flash calibration updates provided for each ECU. If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery." To ensure stable battery voltage, a battery charger may be connected during reprogramming if: ^ Voltage does not fall below 11.4 volts. ^ Voltage does not rise above 16.0 volts. ^ Setting is on SLOW charge and not BOOST. A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.) NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs. Page 4202 9. Remove steering knuckle. A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: Remove grease cap. A. Mount the axle hub in a soft jaw vise. NOTE: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration). B. Using a screwdriver, remove the grease cap. NOTE: Be careful not to damage the grease cap. Page 6247 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 5823 promoters. However, the application of adhesion promoters on earlier model bumpers made from PP/TPU (Polypropylene/Thermoplastic Urethane) and PUR (Polyurethane) is also recommended. Page 4984 SST 09082-00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. 1. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. 2. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. 3. Disconnect the SST from the battery. e. Install the SST. CAUTION: Place the disc wheel on the level ground 1. Connect the connectors of the 2 SST to the steering wheel pad connector. SST 09082-00700, 09082-00760 NOTE: 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. Page 3648 4. REMOVE OIL SEAL Using SST, remove the oil seal. SST 09308-10010 5. REMOVE FRONT BEARING Using SST, remove the front bearing from the drive pinion. SST 09556-22010 6. REMOVE BEARING SPACER a. Remove the 2 washers. b. Remove the bearing spacer. 7. INSTALL NEW BEARING SPACER a. Install a new bearing spacer. b. Install the 2 washers. 8. INSTALL FRONT BEARING a. Place the front bearing. b. Using SST and the companion flange, install the front bearing then remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050) 9. INSTALL NEW OIL SEAL a. Coat a new oil seal lip with MP grease. b. Using SST and a plastic hammer, install the oil seal until its surface is flush with the differential carrier end. SST 09316-12010, 09649-17010 HINT: Connect 2 SST with vinyl tape. Page 6785 Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 6073 Page 611 Page 4573 Page 635 CHART 26 Page 166 During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons: 1. Immobilizer key not properly registered or auto-registration mode left open. 2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure. 3. The Diagnostic Tester cable is damaged, causing an open communication circuit. NOTE: The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable. To eliminate the possibility of the first 2 reasons causing the error message, do the following: 1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility 2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details. To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass. Test CABLE TEST 1. Page 5954 Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST w/ INTERMITTENT If continuity is not as specified, replace the switch. Page 4869 Part 2 of 2 Page 1682 ^ Engine Control Module (ECM) ^ Transmission Control Module (TCM) ^ Or any other Toyota specific control unit Warranty Information Parts Information Required Tools & Equipment NOTE Additional SSTs may be ordered by calling 1-800-933-8335. Process Overview Techstream ECU flash reprogramming is a 4-step process: 1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing the Techstream Health Check function. NOTE Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. 2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only. The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery voltage at 13.5 volts during ECU reprogramming. ECU damage may occur if the correct battery charger mode setting is NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. Page 3882 Steps 1 - 2 Page 896 a. Check only the valves indicated. - Using a feeler gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 10. ADJUST VALVE CLEARANCE a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim. d. Determine the replacement adjusting shim size according to these Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T .......................................................................................................................................................... ................. Thickness of removed shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Service and Repair Valve Guide Seal: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 436 Brake Light Switch: Pinout Values and Diagnostic Parameters ABS A6, A7 ABS SPEED SENSOR FRONT LH, RH 1 - 2 : 1.40 - 1.80 kOhms (20°C, 68°F) A19 ABS SPEED SENSOR REAR 1 - 2 : 0.89 - 1.29 kOhms (20°C, 68°F) 3 - 4 : 0.89 - 1.29 kOhms (20°C, 68°F) A5 ABS ACTUATOR WITH ECU 6 - GROUND : 10 - 14 volts with ignition SW at ON or ST position 24 - GROUND : 10 - 14 volts with stop light SW on (Brake pedal depressed) 2, 18 - GROUND : Always continuity S4 STOP LIGHT SW 2 - 1 : Closed with brake pedal depressed Page 1475 5. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3. Page 141 A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity. ^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables. ^ If there is no continuity, proceed to CABLE TEST 4. CABLE TEST 4. A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver. B. Test J1962 OBDII cable (P/N 02003180) for continuity. ^ If there is no continuity, the cable needs to be replaced. ^ If there is continuity, proceed to CAN Interface Module Test 5. CAN INTERFACE MODULE TEST 5. Page 2753 CHART 5 CHART 6 Page 6677 Transmission Mode Indicator - A/T: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Ground Locations Transmission Mode Indicator - A/T: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 5734 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 5398 Clockspring Assembly / Spiral Cable: Service and Repair Deployment and Disposal Airbag Deployment When Scrapping Vehicle DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. Page 5267 Evaporator Case: Service and Repair Disassembly and Reassembly COOLING UNIT DISASSEMBLY 1. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor. 2. SEPARATE UPPER AND LOWER UNIT CASES a. Disconnect the connector clamp from upper unit case. b. Using a knife, cut off the each packing. c. Remove the 3 clips and 3 screws. d. Separate the upper and lower unit case, then pull out the thermistor from evaporator. 3. REMOVE EVAPORATOR FROM LOWER UNIT CASE HINT: At the time of reassembly, please refer to the following item. If evaporator is replaced, add compressor oil to compressor. Add 40 - 50 cc (1.4 - 1.7 fl.oz) Compressor oil: ND-OIL 8 or equivalent 4. REMOVE EXPANSION VALVE Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve, evaporator and tubes. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) HINT: At the time of reassembly, please refer to the following item. Lubricate 4 new O-rings with compressor oil and install them to the tubes and valve. REASSEMBLY Reassembly is in the reverse order of disassembly. Removal and Installation Steering Gear: Service and Repair Removal and Installation Page 3594 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 4725 Auxiliary Power Outlet: Electrical Diagrams Service Hints CIGARETTE LIGHTER AND POWER OUTLET C7 CIGARETTE LIGHTER 2 - GROUND : Approx. 12 volts with ignition SW at ON or ACC position 1 - GROUND : Always continuity P6, P7 POWER OUTLET 2 - GROUND : Approx. 12 volts with the ignition SW at ON or ACC position 1 - GROUND : Always continuity Page 4167 B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. NOTE: Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of brake vibration on this vehicle. G. Determine if TSB BROO4-02 has already been performed. Repair Procedure No. 1 1. Remove the front wheel. 2. 2WD: Using a screwdriver and hammer remove the grease cap. 3. 4WD: Disconnect drive shaft. A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. Page 2766 CHART 22 Page 4044 Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 4199 B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. NOTE: Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of brake vibration on this vehicle. G. Determine if TSB BROO4-02 has already been performed. Repair Procedure No. 1 1. Remove the front wheel. 2. 2WD: Using a screwdriver and hammer remove the grease cap. 3. 4WD: Disconnect drive shaft. A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. Page 2061 If operation is not as specified, replace the MAF meter. 6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8. Disconnect the MAF meter connector. 4. REINSTALL MAF METER Install the MAF meter with the 2 screws. 5. RECONNECT MAF METER CONNECTOR Page 1057 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTE: Page 4724 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Instruments - Coolant Temperature Gauge Inaccurate Temperature Gauge: All Technical Service Bulletins Instruments - Coolant Temperature Gauge Inaccurate ELECTRICAL EL009-01 October 12, 2001 Title: TEMPERATURE GAUGE INACCURATE Models: '00 - '01 Tundra Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the engine coolant temperature gauge displays an abnormally high reading during normal engine operating temperatures. To address this condition, an updated Temperature Gauge has been made available. Applicable Vehicles ^ 2000 - 2001 model year Tundra trucks, built prior to the VIN shown. Production Change Information Parts Information Repair Procedure IMPORTANT: Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the temperature gauge. 1. Remove the four bolts securing the combination meter assembly. 2. Replace the Temperature Gauge. 3. Reassemble the combination meter. Warranty Information Applicable Warranty *: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Locations EFI Main Relay: Locations Engine Room R/B Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Service and Repair Lifter / Lash Adjuster: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 6711 Splice Location B11 Page 6508 Seat Belt Reminder Buzzer: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 3508 Step 3 Page 4552 a. Install the 4 rubber insulators on the lead wires. NOTE: Be careful of the rubber insulators installation direction. b. Install the rectifier with the 4 screws. Torque: 2.94 N.m (30 kgf.cm, 26 in.lbf) c. Install the cord clip with the nut. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 6. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR a. Place the seal plate on the rectifier end frame. Page 473 Camshaft Position Sensor Page 6087 Paint: Technical Service Bulletins Body - Paintless Dent Repair Information TITLE: PAINTLESS DENT REPAIR SECTION: EXTERIOR BULLETIN # 146 MODELS: TOYOTA, SCION AND LEXUS DATE: SEPTEMBER 2006 Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR) procedures on all Toyota, Scion and Lexus vehicles. PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish issues that may arise. Be sure to choose your PDR service provider carefully and always review their professional qualifications to ensure they are up to date on the latest PDR techniques and procedures. Repair Precautions ^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations where PDR is possible. ^ Pay close attention to the locations of accessories and subassemblies that may utilize wire harnesses or drain hoses, etc. ^ PDR is often complicated by panel contour, placement of reinforcements, and location of electrical and mechanical components. ^ PDR Technicians should be aware of and take the necessary precautions to prevent damage to electrical and mechanical components while performing PDR repairs. General Repair Guidelines ^ The PDR process should only be considered when the exterior paint surface is not broken or cracked. A 30X power hand held microscope (available from most body shop jobbers) should be used to determine if the paint surface shows evidence of cracking. ^ Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion protective coatings. PDR technicians must take steps to prevent corrosion coating damage or restore it with approved equivalent materials. PDR service companies performing PDR repairs should be knowledgeable and capable of restoring corrosion protective coatings damaged during PDR repairs. PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND COLLISION REPAIR TECHNICIANS ^ Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the paint coatings causing delamination (paint coating separation) or micro-cracking. These conditions may not be immediately detectable (use a 30X magnifying hand-held microscope to inspect for cracks). Important: The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes, prying away or cutting reinforcements or welded structural components to gain access to perform a PDR is strictly prohibited and, if done, may void the manufacturer's corrosion protection warranty. ^ Using blocks or wedges between window moldings and door glass (for tool access) is also prohibited. This process can damage window moldings and reduce the factory designed-in pressure of the inner belt molding on the base of the door glass. ^ Window guard protectors must be used to protect window glass during PDR operations. Specific Repair Guidelines ^ Panels with multiple dents, including hail damage, may be considered for PDR as long as the original panel integrity (strength) is maintained. If a panel exhibits any evidence of loss of strength due to the number of dents, the panel should not be considered for PDR. If after performing a PDR repair the panel exhibits evidence of loss of strength, the panel must be repaired using conventional body shop processes. ^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body lines and are no larger than the diameter of a soft ball. ^ Creases that are up to 4 long may be considered for removal. Note: Sharp creases cannot be removed using PDR. ^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter panels may be considered, but extreme caution must Page 5868 Wheel Arch Moulding Page 5303 A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015 and 09870-00025. - Made in USA - Fits both Toyota AC Clamps, used on high and low pressure lines. - Applicable to: 1998 and newer Toyota models - Stainless Steel release pins - Identification and Instructions are laser marked on the handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 4668 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3757 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 6436 Key Reminder Switch: Component Tests and General Diagnostics INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key unlock warning system: INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer sounds. Page 4865 Power Steering Fluid: Service and Repair BLEEDING 1. CHECK FLUID LEVEL 2. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3. TURN STEERING WHEEL With the engine stopped, turn the wheel slowly from lock to lock several times. 4. LOWER VEHICLE 5. START ENGINE Run the engine at idle for a few minutes. 6. TURN STEERING WHEEL a. With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 - 3 seconds, then turn the wheel to the opposite full lock position and keep it there for 2 - 3 seconds. b. Repeat a. several times. 7. STOP ENGINE 8. CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system. 9. CHECK FLUID LEVEL Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Page 4049 A. Disconnect shock absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the 8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint. Page 6802 Splice Location B11 Page 6873 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 409 Glossary Of Terms And Symbols (Part 1) Page 910 11. REMOVE NO.2 TIMING BELT COVER Remove the 2 bolts and No.2 timing belt cover. 12. w/ A/C: DISCONNECT A/C COMPRESSOR FROM ENGINE 13. REMOVE FAN BRACKET Remove the 2 bolts, 2 nuts and fan bracket. 14. IF RE-USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks on the timing belt by turning the crankshaft pulley as shown in the illustration. HINT: If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part. 15. LOOSEN CRANKSHAFT PULLEY BOLT Using SST, loosen the pulley bolt. SST 09213-70010 (90100-08076), 09330-00021 16. SET NO.1 CYLINDER TO TDC/COMPRESSION Page 3472 Electronically Controlled Transmission And A/T Indicator (Part 3) Page 4293 Parts Information Page 612 O2S Application Table O2S Failure Threshold Charts Page 3182 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. Page 1532 Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT 11. REINSTALL THROTTLE BODY COVER Page 5326 Blower Motor Relay: Testing and Inspection HEATER MAIN RELAY INSPECTION 1. REMOVE HEATER MAIN RELAY FROM NO.2 RELAY BLOCK 2. INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 560 CHART 18 CHART 19 Page 2441 Page 5243 a. Check the continuity exists between terminals 1 and 3 of blower switch connector, when turn the mode selector to DEF. position and F/DEF. position. If no continuity exists, proceed to next step. b. Check the continuity exists between terminals of A/C mode switch. If no continuity exists, replace the A/C mode switch. If continuity exists, check or replace heater control housing base. Page 2858 Vehicle Speed Sensor NO.2 Diagram Information and Instructions Relay Box: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 3965 c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 4LO position. d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO -> 4HI position. HINT: When inspecting the operation described, use a heater main relay. NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing. Locations Engine Room R/B Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3042 Fuel Return Line: Service Precautions FUEL TANK AND LINE PRECAUTION - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 632 CHART 24 Recall - Rear Cross-Member Corrosion Technical Service Bulletin # SC90M Date: 091116 Page 1799 Engine Control Module: Service and Repair VEHICLE REPROGRAMMING Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM). Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign provides direction to do so. Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool - Vetronix Mastertech - J2534 Compatible Vehicle Interface (Toyota validated and approved) REPROGRAMMING WITH SCANTOOL Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool, or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the authentic Toyota factory scantool software which runs on either of the above mentioned scantools. Scantool software version requirements are specified in applicable Technical Service Bulletin (TSB)/Service Communication (SC) documents. The Toyota/Lexus factory scantool and/or authentic factory software program cards can be purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card - P/N 01002593-005 for the "stand alone" program card Program cards are provided with the latest production version software available at time of purchase. Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system - Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software - Toyota/Lexus factory scantool program card - PC Interface Cable (P/N 01001090) to transfer data from PC to scantool - Calibration CD (00456-REPRG-001) REPROGRAMMING WITH J2534 INTERFACE Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface - Toyota Calibration Update Wizard software (available on calibration CD) - Personal Computer running Microsoft Windows 2000/XP or later operating system - Calibration CD (00456-REPRG-001) Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on this list. Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that their hardware works safely and efficiently with their products. Every device listed on this page has been thoroughly tested and validated on Toyota, Scion and Lexus vehicles. It is important to understand that only the specific devices, firmware, DLLs and APIs listed here have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware, DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's control; in some cases, changes made to device hardware/software can negatively impact reprogramming performance. Toyota makes every effort to continue to work with J2534 interface manufacturers to ensure continued product compatibility as the respective products evolve. Requirement for device: Supplier Device Name Version (Firmware* / DLL* / API*) Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04) Actia PassThru+ XS (02.01 / 02.01 / 04.04) Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04) EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04) Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04) Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04) * Original validated firmware/DLL versions may be superceded by the device manufacturer. Contact the device manufacturer if you are unable to find the versions listed above. Support OS: OS Name and Version: Engine - Squealing Noise On Cold Start Up Drive Belt: Customer Interest Engine - Squealing Noise On Cold Start Up ENGINE EG003-05 Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE Models: '00 - '05 Tundra & '01 - '05 Sequoia February 9, 2005 Introduction Some customers may experience abnormal squeal noise from the engine accessory drive belt area, usually during cold start-up. An improved accessory drive belt has been developed to correct this condition. Applicable Vehicles ^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. ^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the Production Change Effective VIN shown below. Production Change Information Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure Replace the accessory drive belt with the improved part. 1. Remove existing accessory drive belt. Page 3963 a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4 switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and the 4HI indicator lights come on when the touch select high-low switch is in OFF position. HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position. - If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash. 3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals. Touch select 2-4 switch Touch select high-low switch: If continuity is not as specified, replace the center integration panel assembly. 4. INSPECT ACTUATOR RESISTANCE a. Using an ohmmeter, measure the resistance between terminals 1 and 2. Standard resistance: 0.3 - 100 Ohms b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground. Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the actuator assembly. Page 2402 A/F and 02 Sensor Identification Page 3716 2WD and 4WD front propeller shaft: b. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. 7. CHECK SPIDER BEARING a. Check that the spider bearing moves smoothly. Body - Paintless Dent Repair Information Paint: Technical Service Bulletins Body - Paintless Dent Repair Information TITLE: PAINTLESS DENT REPAIR SECTION: EXTERIOR BULLETIN # 146 MODELS: TOYOTA, SCION AND LEXUS DATE: SEPTEMBER 2006 Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR) procedures on all Toyota, Scion and Lexus vehicles. PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish issues that may arise. Be sure to choose your PDR service provider carefully and always review their professional qualifications to ensure they are up to date on the latest PDR techniques and procedures. Repair Precautions ^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations where PDR is possible. ^ Pay close attention to the locations of accessories and subassemblies that may utilize wire harnesses or drain hoses, etc. ^ PDR is often complicated by panel contour, placement of reinforcements, and location of electrical and mechanical components. ^ PDR Technicians should be aware of and take the necessary precautions to prevent damage to electrical and mechanical components while performing PDR repairs. General Repair Guidelines ^ The PDR process should only be considered when the exterior paint surface is not broken or cracked. A 30X power hand held microscope (available from most body shop jobbers) should be used to determine if the paint surface shows evidence of cracking. ^ Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion protective coatings. PDR technicians must take steps to prevent corrosion coating damage or restore it with approved equivalent materials. PDR service companies performing PDR repairs should be knowledgeable and capable of restoring corrosion protective coatings damaged during PDR repairs. PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND COLLISION REPAIR TECHNICIANS ^ Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the paint coatings causing delamination (paint coating separation) or micro-cracking. These conditions may not be immediately detectable (use a 30X magnifying hand-held microscope to inspect for cracks). Important: The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes, prying away or cutting reinforcements or welded structural components to gain access to perform a PDR is strictly prohibited and, if done, may void the manufacturer's corrosion protection warranty. ^ Using blocks or wedges between window moldings and door glass (for tool access) is also prohibited. This process can damage window moldings and reduce the factory designed-in pressure of the inner belt molding on the base of the door glass. ^ Window guard protectors must be used to protect window glass during PDR operations. Specific Repair Guidelines ^ Panels with multiple dents, including hail damage, may be considered for PDR as long as the original panel integrity (strength) is maintained. If a panel exhibits any evidence of loss of strength due to the number of dents, the panel should not be considered for PDR. If after performing a PDR repair the panel exhibits evidence of loss of strength, the panel must be repaired using conventional body shop processes. ^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body lines and are no larger than the diameter of a soft ball. ^ Creases that are up to 4 long may be considered for removal. Note: Sharp creases cannot be removed using PDR. ^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter panels may be considered, but extreme caution must Page 5009 a. Lift up the vehicle. b. Place the lever under the tire, and inspect the tree play while lifting the tire using a wooden stick, etc., as a fulcrum. 3. Inspect the Suspension Arm Ball Joint Free Play A. Lift up the vehicle B. Inspect the free play while moving the control arm by hand. (Reference) Free Play Inspection Method (Gauge Installation) ^ Position the dial gauge between the arm (upper or lower) and the knuckle, and measure free play. (This illustration shows how to measure free play for vehicles with double wishbone type suspension with coil spring.) 4. Inspect Ball Joint Dust Cover Check for cracks and grease leaks on the dust cover (boots). Turning Torque Inspection Inspect Ball Joint Turning Torque Move the stud back and forth 5 times, and then turn the stud continuously at 3-5 seconds per turn, and measure the turning torque at the 5th turn. HINT: Refer to the table for standard values for the turning torque. Page 2190 Crankshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 6.5 N.m (65 kgf.cm, 58 in.lbf) Page 6340 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 1511 REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE TIMING BELT 3. REMOVE NO.2 IDLER PULLEY Page 1439 b. Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing downward. c. Measure the protrusion of the push rod from the housing end. Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 inch) If the protrusion is not as specified, replace the tensioner. 4. INSPECT WATER PUMP INSTALLATION 1. INSTALL CRANKSHAFT TIMING PULLEY a. Align the timing pulley set key with the key groove of the pulley. b. Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-46011 2. INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY a. Apply adhesive 2 or 3 threads of the pivot bolt. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using a 10 mm hexagon wrench, install the plate washer and No.1 idler pulley with the pivot bolt. Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the No.2 idler pulley with the bolt. Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.) d. Check that the No.1 and No.2 idler pulleys moves smoothly. Page 5019 Ball Joint: Service and Repair Upper REMOVAL 1. REMOVE STEERING KNUCKLE WITH AXLE HUB Page 4410 Hydraulic Control Assembly - Antilock Brakes: Diagrams ABS ACTUATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Part 1 of 2 Testing and Inspection Blower Motor Resistor: Testing and Inspection BLOWER RESISTOR INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS 2. REMOVE LOWER NO.2 FINISH PANEL 3. REMOVE LOWER CENTER COVER 4. REMOVE LOWER LH FINISH PANEL 5. REMOVE LOWER COVER 6. REMOVE NO.4 HEATER TO REGISTER DUCT 7. REMOVE BLOWER RESISTOR a. Disconnect the connector. b. Remove the 2 screws and blower resistor. 8. INSPECT BLOWER RESISTOR RESISTANCE If resistance is not as specified, replace the blower resistor. 9. INSTALL BLOWER RESISTOR a. Install the blower resistor with the 2 screws. b. Connect the connector. 10. INSTALL NO.4 HEATER TO REGISTER DUCT Page 5765 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Brakes - Vibration From Rear Brake Shoe: All Technical Service Bulletins Brakes - Vibration From Rear BRAKES BR001-01 January 12, 2001 Title: REAR BRAKE VIBRATION Models: '00 - '01 Tundra TSB Update Notice: The information contained in this TSB updates BR006-00, dated November 17, 2000. Revised text is underlined. New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the star wheel adjuster has been reduced from 30 to 26 teeth. Applicable Vehicles ^ 2000 - 2001 model year Tundra vehicles. Production Change Information Parts Information Repair Procedure 1. Grind rear brake drums with brake lathe to within serviceable limits. 2. If the drums are unserviceable or above maximum inside diameter, replace the drums. 3. If there is uneven wear on the lining, replace the left and right brake shoes. 4. Replace the parking brake shoe strut sets. 5. Adjust the parking brake to specifications. 6. Reinstall the rear wheels, and torque wheel nuts to: Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf) 7. Road test. Warranty Information Page 3958 b. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the 3 clamps with the 3 bolts. 7. FILL ATF AND CHECK FLUID LEVEL Page 5639 e. Install the front pillar garnish. 1. Install the front pillar garnish. 2. Using a torx driver, install the assist grip with the 2 torx screws. Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool) 3. Install the caps. f. Install the front door scuff plate with 5 screws. Page 5637 a. Install the retractor of front seat outer belt. 1. Install the retractor of front seat outer belt with the bolt. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) 2. Connect the pretensioner connector as shown in the illustration. b. Install the front door rear scuff plate and cover. 1. Install the front door rear scuff plate with the clip. 2. Install the cover with the clip. c. Install the roof side rail garnish. 1. Install the roof side rail garnish. 2. Using a torx driver, install the assist grip with the 2 torx screws. Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool) 3. Install the caps. d. Install the front seat outer belt shoulder anchor. 1. Install the front seat outer belt shoulder anchor with the bolt. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) 2. Install the cap. e. Install the front seat outer belt floor anchor with the bolt. Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) f. Install the rear door scuff plate with the 3 screws. g. Install the front door scuff plate with the 4 screws. 2. Standard cab: INSTALL FRONT SEAT OUTER BELT Page 1700 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 4997 Steering Wheel: Service and Repair Steering Wheel Off Center Procedures REPAIR PROCEDURES HINT: This is the repair procedure for steering off center. 1. INSPECT STEERING WHEEL OFF CENTER a. Apply masking tape on the top center of the steering wheel and steering column upper cover. b. 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. c. Draw a line on the masking tape as shown in the illustration. d. Turn the steering wheel to its straight position. HINT: Refer to the upper surface of the steering wheel, steering spoke and SRS airbag line for the straight position. Page 4182 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Repair Procedure Page 6262 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5030 d. Using SST, a press and steel plate, install a new No2 bushing. SST 09631-12090, 09950-60020 (09951-00680) HINT: Before installing the bushing, set it in the correct direction, as shown in the illustration. 2. REPLACE NO.1 AND NO.2 SPRING BUMPERS ON-VEHICLE a. Remove the front wheel. b. Using SST, replace the No.1 spring bumper. SST 09922-10010 HINT: At the time of installation, use a torque wrench with a fulcrum length of 345 mm (13.58 inch). Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.) c. Replace No.2 spring bumper. 1. Remove the stabilizer bar. 2. Using SST, replace the No.2 spring bumper. SST 09922-10010 HINT: At the time of installation, use a torque wrench with a fulcrum length of 345 mm (13.58 inch). 3. Install the stabilizer bar d. Install the front wheel. Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) INSTALLATION 1. INSTALL LOWER SUSPENSION ARM TO CHASSIS FRAME Install the lower suspension arm with the 2 cams, bolts and cam plates while slightly shifting the power steering gear rearward. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) NOTICE: Do not damage the power steering gear tubes. HINT: After stabilizing the suspension, align the matchmarks on the front and rear cam plates and chassis frame, and torque the bolts. Testing and Inspection Cargo Lamp Switch: Testing and Inspection INSPECT CARGO LIGHT SWITCH CONTINUITY a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster integration. c. Check the continuity exists between terminal 12 and terminal 1, with the switch ON. d. Check that no continuity exists between terminal 12 and terminal 1, with the switch OFF. If continuity is not as specified, replace the switch. Page 2276 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Specifications Wheel Fastener: Specifications Wheel Nut Torque 110 Nm (83 ft.lb) Page 2670 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. Page 1110 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 4908 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 2434 CHART 21 Page 6820 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5544 Technical Service Bulletin # BO002-01 Date: 010126 Seat Belts - Extenders BODY BO002-01 January 26, 2001 Title: SEAT BELT EXTENDER Models: '99 - '01 Model Year TSB UPDATE NOTICE: The information contained in this TSB updates B0020-00 dated August 11, 2000. Revised text is underlined. Introduction Toyota customers who find it necessary to increase the length of their seal belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. ^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. ^ The extender is available only in black. ^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label and review the Owner Instruction Sheet" with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer's file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do not stock Seat Belt Extenders due to the need for proper fitting to individual customers. This bulletin contains the following information: Procedure and Sample Label Application Charts Part Number Information Owner Instructions Seat Belt Extender Worksheet Applicable Vehicles ^ 1999 through 2001 model year Toyota vehicles. Page 6433 Key Reminder Switch: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Page 169 A. Test the CAN Interface Module (P/N 01002744) for continuity. ^ If there is no continuity, the CAN Interface Module needs to be replaced. ^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables. Page 3286 b. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) c. Install the 3 clamps with the 3 bolts. 7. FILL ATF AND CHECK FLUID LEVEL Page 789 Step 3 Page 6223 Cruise Control: Testing and Inspection Cruise Control System Check Sheet Page 4067 ^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. REMOVE BEARING FROM STEERING KNUCKLE A. Using snap ring pliers, remove the snap ring. B. Using the following SSTs and a press, remove the bearing from the steering knuckle. ^ 09950-60020 (09951-00810) ^ 09950-70010 (09951-07150) 16. INSTALL NEW BEARING A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle. ^ 09527-17011 ^ 09950-60020 (09951-00910) Page 400 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 2210 Data Link Connector: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 5555 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 6346 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 5883 Upper Side Moulding / Trim: Service and Repair Roof Drip Side Finish Moulding ROOF DRIP SIDE FINISH MOULDING Roof Drip Side Finish Moulding COMPONENTS REMOVAL 1. REMOVE ENDS OF MOULDING Locations Page 4712 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 3714 HINT: Remove the bearing on the opposite side in the same procedure. 4. SELECT SPIDER BEARING Select the appropriate bearing according to the existence of drill mark on the yoke. 5. INSTALL SPIDER BEARING a. Apply MP grease to a new spider and bearings. HINT: Be careful not to apply too much grease. b. Align the matchmarks on the yoke and shaft. c. Fit the spider into the yoke. d. Using SST, install the bearing on the spider. SST 09332-25010 e. Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal in width. Page 4993 Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTE: The tires may be marked by the airbag deployment, so use the redundant tires. f. Deploy the airbag. 1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. 3. Press the SST activation switch and deploy the air- bag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. g. Dispose the steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Disposing of Steering Wheel Pad With Airbag Deployed DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air-bag 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 steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. Specifications Output Shaft: Specifications Output Shaft Thrust Play 0.27 - 0.86 mm Page 5964 Page 6352 Clock: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 24 Splice Location B11 Page 4547 Alternator: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE REAR END COVER a. Remove the nut and terminal insulator. b. Remove the bolt 3 nuts, plate terminal and end cover. 2. REMOVE BRUSH HOLDER a. 100 A type: Remove the brush holder cover from the brush holder. b. Remove the 2 screws and brush holder. c. Remove the seal plate from the rectifier end frame. 3. REMOVE VOLTAGE REGULATOR Remove the 3 screws and voltage regulator. 4. REMOVE RECTIFIER HOLDER Page 2614 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 2367 Knock Sensor: Service and Repair 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 Disconnect the knock sensor connectors. 1. REPLACE THE SENSOR WITH SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) Reconnect the knock sensor connectors. 2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 4. REINSTALL INTAKE AIR CONNECTOR 5. REINSTALL THROTTLE BODY COVER Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 5791 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 2621 A. The new calibration file should be displayed as the current ECU calibration file. B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22). C. Affix this label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60-90 seconds for ink to set before handling. Page 2571 memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester Program Card to make room for the new calibration file. If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE. NOTE: If there is adequate memory to store the calibration file, skip to Step J. I. The CUW will now delete the calibration file(s) selected (see Figure 12). Page 6662 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Testing and Inspection Parking Brake Lever: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel at 196 N (20 kgf, 44 lbs.): 6 - 14 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 3. (a) Tighten one of the adjusting nuts of the intermediate lever while loosening the other one until the travel is correct. Tighten the 2 adjusting nuts. (b) After adjusting the parking brake, confirm that the bellcrank stopper screw comes into contact with the backing plate. For shoe clearance adjustment, see step 3 on page Page 2504 CHART 28 Engine Controls - Error When Reprogramming ECU Engine Control Module: All Technical Service Bulletins Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Specifications Fluid Pan: Specifications Oil Pan W/ Bolts 7.4 Nm Page 4418 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly Page 6675 Glossary Of Terms And Symbols (Part 1) Page 6680 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 4788 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4463 Vacuum Brake Booster: Testing and Inspection ON-VEHICLE INSPECTION 1. OPERATING CHECK (a) Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. (b) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 2. AIR TIGHTNESS CHECK (a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. Page 1872 Step 1 Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 477 4. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor. INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 2. INSTALL LH NO.3 TIMING BELT COVER 3. INSTALL DRIVE BELT 4. FILL ENGINE COOLANT 5. CHECK ENGINE COOLANT FOR LEAKS 6. CHECK IGNITION TIMING Page 2433 Page 1630 Page 3724 Flex Plate: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Torque Converter; Service and Repair. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 5178 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 2WD: INSTALL GREASE CAP 8. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Lightly strike the SST on its circumference evenly. b. Coat MP grease to the oil seal lip. Page 4910 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 3754 Glossary Of Terms And Symbols (Part 1) Page 221 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 4416 REMOVAL 1. REMOVE BRAKE LINE COVER 2. DISCONNECT CONNECTOR Pull out the release bar, and disconnect the connector. 3. DISCONNECT BRAKE LINES Using SST, disconnect the 5 brake lines from the ABS actuator. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 4. REMOVE ABS ACTUATOR ASSEMBLY Remove the 3 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.) 5. REMOVE ABS ACTUATOR (a) Remove the 3 nuts and ABS actuator from the actuator bracket. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) (b) Remove the 3 holders and 3 cushions from the ABS actuator. INSTALLATION Page 236 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 1172 b. Install the LH camshafts. 1. Apply MP grease to the thrust portion of the intake and exhaust camshafts. 2. Place the intake and exhaust camshafts. 3. Engage the intake gear to the exhaust gear by meeting the timing marks (2 dot marks) on each gear. 4. Remove any old packing (FIPG) material. 5. Apply seal packing to the front bearing cap. Seal packing:Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 1.5 mm (0.06 inch) opening. - Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. - Immediately remove nozzle from the tube and reinstall cap. NOTICE: Do not apply seal packing to the front bearing cap grooves. 6. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. 7. Install the other bearing cap in the sequence shown with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. 8. Push in the camshaft oil seal. Engine Controls - Bank 1/Bank 2 O2 Sensor identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 2654 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Page 4675 Driver Side J/B And Integration Relay Inner Circuit Page 2807 Page 884 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 2297 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 2549 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 20 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 3507 Steps 1 - 2 Page 5201 Blower Motor: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE BLOWER MOTOR Remove the 3 screws and blower motor. 2. REMOVE AIR INLET SERVOMOTOR Remove the 3 screws and servomotor. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 3746 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 6266 Audible Warning Device: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2730 Applicable Vehicles Page 2570 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection INSPECT FOG LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Engine Controls - Techstream(R) ECU Re-Flash Procedure Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU Re-Flash Procedure T-SB-0064-10 February 4, 2010 Techstream ECU Flash Reprogramming Procedure Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. SS002-07. ^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. ^ A new section, Techstream Preparation, has been added. ^ Techstream Lite has been added as an option in Required Tools & Materials. ^ Process Overview and Operation Procedure sections have been updated. TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information. ECU Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard references: ^ Powertrain Control Module (PCM) Page 5537 Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on Seat Belt Extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result In reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. ^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the extender and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. Page 5712 Instrument Panel Ground Location IE Left Kick Panel IF Left Kick Panel IG Instrument Panel Brace RH IH Right Kick Panel II Right Kick Panel Body Ground Location (Access Cab) Page 5294 3. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES a. Using pliers, grip the claw of clip and slide the clip along the hose. b. Disconnect the water hoses. HINT: At the time of installation, please refer to the following items. Push the water hose onto the heater radiator pipe as far as the second ridge on the pipe. - Install the hose clip in a position, as shown in the illustration. 4. REMOVE INSTRUMENT PANEL AND REINFORCEMENT. 5. REMOVE DEFROSTER NOZZLE AND HEATER TO REGISTER DUCT Access Cab, Standard Cab Shown 6. REMOVE HEATER UNIT Remove the 3 nuts and heater unit. INSTALLATION Installation is in the reverse order of removal. Page 617 CHART 8 CHART 9 Page 1884 Applicable Vehicles Page 2417 Page 4330 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Repair Procedure Page 4760 Driver Side J/B And Integration Relay Page 4562 Page 4018 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 3471 Electronically Controlled Transmission And A/T Indicator (Part 2) Page 6844 Lamp Control Module: Description and Operation LIGHT AUTO TURN OFF SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 9 of the integration relay through ECU IG fuse. Voltage is applied at all times to TERMINAL 6 of the integration relay through the TAIL fuse, and through the HEAD relay coil side [w/o daytime running light] or through the daytime running light relay (Main) [w/ daytime running light]. 1. NORMAL LIGHTING OPERATION With the light control SW turned to TAIL position, a signal is input into the integration relay. Due to this signal, the current flowing to TERMINAL 6 of the relay flows to TERMINAL 14 of the light control SW to TERMINAL 16 to GROUND, and taillights to turn on. With the light control SW turned to HEAD position, a signal is input into the integration relay. Due to this signal, the current flowing to the relay flows to TERMINAL 13 of the light control SW to TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the lights on. The taillight circuit is same as above. 2. LIGHT AUTO TURN OFF OPERATION With light on and ignition SW turned off (Input signal goes to TERMINAL 9 of the relay), when the driver's door is opened (Input signal goes to TERMINAL 14 of the relay), the relay operates and the current is cutoff which flows from TERMINAL 6 of the relay to taillight circuit and headlight circuit. As a result, all lights are turned off automatically. Page 509 Steps 2 - 3 INSPECTION PROCEDURE HINT: - DTC P0325 is for the left bank knock sensor circuit. - DTC P0330 is for the right bank knock sensor circuit. - Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as 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. Page 3171 Camshaft Position Sensor Page 3687 DISASSEMBLY 1. 2WD: REMOVE GREASE CAP a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 2. 4WD: REMOVE OIL SEAL (INSIDE) a. Mount the axle hub in a soft jaw vise. HINT: Close the vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). Page 1146 Wheel Bearing: Tools and Equipment Wheel Bearing Nut Socket AST tool# TOY 185 Page 2170 Camshaft Position Sensor: Mechanical Specifications Torque: ................................................................................................................................................ .................................. 7.5 N.m (80 kgf.cm, 66 in.lbf) Page 779 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Specifications Firing Order: Specifications Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2 Page 4916 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 2805 Page 2875 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 754 Impact Sensor: Service and Repair Removal and Installation Front Airbag Sensor REMOVAL NOTE: - If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded. - Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. - Never reuse the sensor involved in a collision when the SRS has deployed. - Never repair a sensor in order to reuse it. Page 6289 Instrument Panel Connector Location IA1 Engine Room Main and Cowl Wire (Left Kick Panel) IA2 Engine Room Main and Cowl Wire (Left Kick Panel) IA3 Engine Room Main and Cowl Wire (Left Kick Panel) IA4 Engine Room Main and Cowl Wire (Left Kick Panel) IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel) IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel) Instrument Panel Connector Location ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH) IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel) IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel) IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel) Page 2493 CHART 22 Page 3554 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 4931 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2342 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 204 D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7). NOTE: If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6). Page 2392 Page 2203 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4392 Brake Caliper: Specifications Caliper Anchor Bolts 123 Nm Bleeder Screw 11 Nm Hydraulic Brake Line 15 Nm Page 4315 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Page 5837 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. Note: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative. Inspection Seat Belt Tensioner: Testing and Inspection Inspection INSPECTION 1. PRETENSIONER IS NOT ACTIVATED a. Perform a diagnostic system check. b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Standard cab: Check for cuts and cracks in, or marked discoloration on the quarter trim. - Access cab: Check for cuts and cracks in, or marked discoloration on the front door rear scuff plate. - Check for cuts and cracks in wire harness, and for chipping in connectors. - Standard cab: Check for deformation of the quarter panel. - Access cab: Check for deformation of the ELR bracket. Page 2540 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 6670 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 1721 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 3155 Knock Sensor (Part 2) Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER 3. DRAIN DIFFERENTIAL OIL Specifications Wheel Fastener: Specifications Wheel Nut Torque 110 Nm (83 ft.lb) Electrical Specifications Page 4783 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2026 Vehicle Speed Sensor NO.2 Page 1849 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Page 5157 Wheel Bearing: Tools and Equipment Wheel Bearing Nut Socket AST tool# TOY 185 Page 6721 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 5018 4. REMOVE LOWER BALL JOINT a. Remove the cotter pin and nut from the lower ball joint. b. Using SST, disconnect the lower ball joint from the lower suspension arm. SST 09628-62011 c. Remove the 4 lower ball joint set bolts. d. While lifting the upper suspension arm and steering knuckle, remove the lower ball joint. e. Support the upper suspension arm and steering knuckle securely. INSPECTION 1. INSPECT LOWER BALL JOINT BOOT FOR DAMAGE 2. INSPECT LOWER BALL JOINT FOR ROTATION CONDITION a. As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn per 2 - 4 seconds and take the torque reading on the 5th turn. Turning torque: 0.1 - 2.5 Nm (11 - 25 kgf-cm, 1 - 22 inch lbs.) INSTALLATION 1. INSTALL LOWER BALL JOINT a. While lifting the upper suspension arm and steering knuckle, install the lower ball joint. b. Temporarily install the 4 bolts to the lower ball joint. c. Install the set nut to hold the lower ball joint to the lower suspension arm and a new cotter pin. Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 2. CONNECT TIE ROD END Connect the tie rod end to the lower ball joint with the nut and a new cotter pin. Torque: 91 Nm (930 kgf-cm, 67 ft. lbs.) If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 3. TIGHTEN LOWER BALL JOINT SET 4 BOLTS Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 4. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 5. CHECK FRONT WHEEL ALIGNMENT Page 1319 Engine Oil: Service and Repair REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. w/ Oil filter change: REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil drain plug and gasket, and drain the oil into a container. 3. REPLACE OIL FILTER a. Using SST, remove the oil filter. SST 09228-07501 b. Clean the oil filter contact surface on the oil filter mounting. c. Lubricate the filter rubber gasket with clean engine oil. d. Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. e. Using SST, give it an additional 3/4 turn to seat the filter. SST 09228-07501 Page 1236 5. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3. Page 3270 Step 4 O/D OFF indicator light does not light up Steps 1 - 2 O/D OFF indicator light remains ON Locations VSV For Evaporative Emission (EVAP) Page 3708 b. Install the spacer. c. Place the flange on the shaft and align the matchmarks. HINT: If replacing either the center flange or intermediate shaft, reassemble it so that the front side flange yoke of the intermediate shaft and the rear side flange yoke of the propeller shaft are facing in the same direction. d. Install the spacer. e. Using SST to hold the flange, press the bearing into position by tightening down a new nut. SST 09330-00021 Torque: 181 Nm (1,845 kgf-cm, 133 ft. lbs.) f. Loosen the nut. g. Torque the nut again. Torque: 82 Nm (835 kgf-cm, 60 ft. lbs.) h. Using a hammer and punch, stake the nut. 3. Rear propeller shaft: INSTALL PROPELLER SHAFT a. Align the matchmarks on the flanges and connect the flanges with 4 bolts, washers and nuts. HINT: If replacing either the center flange or intermediate shaft, reassembly it so that the front side flange yoke of the intermediate shaft and the rear side flange yoke of the propeller shaft are facing in the same direction. b. Torque the bolts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) INSTALLATION 1. INSTALL FRONT PROPELLER SHAFT a. Align the matchmarks on the propeller shaft and differential flanges, and connect the flanges with the 4 bolts, nuts and washers. b. Torque the 4 bolts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) c. Align the matchmarks on the propeller shaft and transfer flanges, and connect the flanges with the 4 nuts and washers. d. Torque the 4 nuts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) 2. INSTALL REAR PROPELLER SHAFT Page 18 Audible Warning Device Control Module: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 5144 b. Install the shock absorber, cushion and retainer with nut. Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.) c. Install the lower side of the shock absorber with bolt and nut. Torque: 87 Nm (890 kgf-cm, 64 ft. lbs.) 2. INSTALL REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 3. REMOVE SAFETY STANDS A/T - Torque Converter Bolt Installation Precautions Flex Plate: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 4098 11. 4WD: Remove oil seal (inside). A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to the illustration above). B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. Remove axle hub from steering knuckle. A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. SST P/N: 09710-28012-01 (09710-07031) SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) HINT: If necessary, use a press to remove the axle hub from the steering knuckle. C. Remove the dust cover from the steering knuckle. D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without ABS). NOTE: Take care not to scratch the serration of the speed sensor rotor. 14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 15. Remove bearing from steering knuckle. Page 3159 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE THROTTLE BODY COVER 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS 4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 5. INSPECT KNOCK SENSOR 1,2 a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor with SST. SST 09816-30010 Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) c. Reconnect the knock sensor connectors. 6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY 7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS 8. REINSTALL INTAKE AIR CONNECTOR 9. REINSTALL THROTTLE BODY COVER Electrical - SRS And HV Wiring Repairs Air Bag Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 5988 - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Specifications Brake Fluid: Specifications Required Brake Fluid FMVSS No. 116 DOT3 Page 2446 CHART 28 Page 3456 Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in wire routing is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR = Brown SB = Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2318 E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded. NOTE: The calibration type is specific to the software version loaded on your Diagnostic Tester. If you selected the wrong version when downloading the calibration file, you will receive an error when attempting to install the file on the Diagnostic Tester. Page 6274 Audible Warning Device: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Page 641 CHART 30 Page 1798 Terminals Of ECU - Connector Pinouts (Part 2) INSPECTION 1. REMOVE ECM 2. INSPECT ECM 3. REINSTALL ECM Page 1284 A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the accessory drive belt tensioner to release tension and remove the accessory drive belt. HINT: The pulley bolt for the belt tensioner has a left hand thread. B. Using the accessory drive belt routing label located on the passenger side of the radiator core support as a guide, install the new accessory drive belt. 2. Check belt tensioner operation. A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force. B. Ensure proper alignment of the belt with the ribbed grooves of each pulley. C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each pulley. D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see illustration). E. If the arrow mark falls outside area "A," the drive belt is incorrect. HINT: When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect. Page 3946 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Page 3520 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Page 2697 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 2910 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2625 Engine Control Module (ECM) Page 857 Fuel Pressure: Testing and Inspection CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the front fuel pipe from the LH delivery pipe. d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and SST (adapter). SST 09268-45014 (09268-1190, 90405-06167) Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) e. Wipe off any splattered gasoline. f. Reconnect the negative (-) terminal cable to the battery. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a) to (e)) h. Measure the fuel pressure. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. i. Disconnect the TOYOTA hand-held tester from the DLC3. j. Start the engine. k. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) l. Stop the engine. m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45014 o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable to the battery. q. Check for fuel leaks. Page 422 Key Reminder Switch: Component Tests and General Diagnostics INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key unlock warning system: INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer sounds. Page 4214 Parts Information Diagnosis Procedure 1. Confirm the customer complaint. 2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving). The following procedure will isolate the drum brakes from the rest of the hydraulic system by using the parking brake (PKB). NOTE: Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time to disengage the parking brake. HINT: When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be pressed to the desired level for continued diagnosis. A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph. B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not apply the PKB past this point of initial engagement. C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle speed and allow adequate time to monitor the ride condition. D. Disengage the PKB. E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one source of brake vibration on this vehicle. Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration. F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake vibration on this vehicle. Proceed to the following repair procedure. Repair Procedure Page 6543 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 5049 Page 1554 Heater Control Valve: Testing and Inspection WATER VALVE ON-VEHICLE INSPECTION 1. WARM UP ENGINE 2. DISCONNECT WATER VALVE CONTROL CABLE 3. INSPECT WATER VALVE OPERATION a. Check that warm air blown out the vent when the water valve lever is moved to "WARM" position. b. Check that cool air blown out when the water valve is moved to the "COOL" position. If operation is not as specified, replace the water valve. 4. CONNECT WATER VALVE CONTROL CABLE Page 4010 Wheel Speed Sensor: Diagrams Page 3691 Wheel Bearing: Tools and Equipment Wheel Bearing Nut Socket AST tool# TOY 185 For R and R of wheel bearing nut located on inboard side of wheel hub. Applicable: Newer Toyota trucks and SUV's (2wd only). - Made in USA Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 246 EFI Main Relay: Testing and Inspection EFI MAIN RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE EFI MAIN RELAY (Marking: EFI) 3. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 4. INSPECT EFI MAIN RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Page 2479 CHART 2 CHART 3 CHART 4 Page 1632 2. DISCONNECT WATER INLET FROM WATER INLET HOUSING Remove the 3 nuts and disconnect the water inlet from the water inlet housing. 3. REMOVE THERMOSTAT a. Remove the thermostat. b. Remove the gasket from the thermostat. INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. a. Immerse the thermostat in water and gradually heat the water. b. Check the valve opening temperature. Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as specified, replace the thermostat. c. Check the valve lift. Valve lift: 10 mm (0.39 inch) or more at 95°C (203°F) 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 40°C (104°F)). If not closed, replace the thermostat. INSTALLATION Page 6202 Glossary Of Terms And Symbols (Part 1) Page 2632 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4332 A. Remove the bolt and brake line clamp from the steering knuckle. B. Remove the 2 bolts, brake caliper and disc. 7. REMOVE SHOCK ABSORBER A. Disconnect Shock Absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the bolt. C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the brake tube. 8. DISCONNECT LOWER BALL JOINT Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle opening angle and a malfunction of the throttle position sensor's own. Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals output from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve opening angle properly in accordance with the driving condition. If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the throttle valve can be controlled by the accelerator pedal through the throttle cable. Page 4371 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 600. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 1508 Part 3 of 3 Page 4741 Engine Compartment Instrument Panel Locations Page 6526 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3890 BJ Inside of Rear Door LH BK Inside of Rear Door RH BL Surrounding of the Front of the Fuel Tank Connector Location BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 6057 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. Note: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative. Page 544 Page 2876 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Description and Operation Transmission Position Switch/Sensor: Description and Operation PARK / NEUTRAL POSITION SWITCH Engine Control System The park/neutral position switch comes on when the shift lever is in the N or P position. When it comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage and 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. Transmission Control System The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch. Testing and Inspection Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise, check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Page 668 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2774 Ground Locations Horn: Ground Locations Engine Compartment Ground Location EA Front Left Fender EB Rear Bank of Right Cylinder EC Rear Bank of Left Cylinder Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 6714 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 1782 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Specifications Timing Belt Tensioner: Specifications Timing Belt Tensioner Torque ................................................................................................................................................. ........................................................................ 26 Nm Page 5760 Body Splice Location (Standard Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B10 Frame Wire Seat Page 1690 Then click Next. F. Verify correct current calibration and new calibration information. Then click Next. NOTE ^ The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. ^ Each calibration file may contain up to three separate calibrations. Page 4928 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4487 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 5718 Radio/Stereo: Harness Locations Engine Compartment Connector Location EA1 Cowl Wire Harness and Wire Harness (Connector Location) EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EC1 Engine No. 2 Wire and Engine Wire (Near the Starter) EC2 Engine No. 2 Wire and Engine Wire (Near the Starter) EC3 Engine No. 2 Wire and Engine Wire (Near the Starter) ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission) Page 4949 7. DISCONNECT PRESSURE FEED AND RETURN TUBES Using Special Service Tool (SST), disconnect the tube. SST 09023-12700 8. REMOVE PS GEAR ASSEMBLY a. Remove the bolt, nut and stud bolt from the bracket. b. Remove the 2 set bolts, nut, washer and PS gear assembly. 9. REMOVE BRACKET AND GROMMET INSTALLATION 1. INSTALL GROMMET AND BRACKET 2. INSTALL PS GEAR ASSEMBLY a. Install the PS gear assembly with the gear assembly set bolt. Torque: 165 Nm (1,700 kgf-cm, 123 ft. lbs.) b. Install the gear assembly set bolt, washer and nut. Torque: 130 Nm (1,350 kgf-cm, 96 ft. lbs.) c. Install the stud bolt to the bracket. Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.) d. Install the bolt and nut to the bracket. Torque: 165 Nm (1,700 kgf-cm, 123 ft. lbs.) 3. CONNECT PRESSURE FEED AND RETURN TUBES Using Special Service Tool (SST), connect the tubes. SST 09023-12700 Torque: 32 Nm (326 kgf-cm, 27 ft. lbs.) HINT: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch). ^ This torque value is effective in case that SST is parallel to a torque wrench. 4. CONNECT CLAMP PLATE Connect the clamp plate and install the bolt. Torque: 29 Nm (290 kgf-cm, 21 ft. lbs.) 5. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY 6. CONNECT RIGHT-HAND AND LEFT-HAND TIE ROD ENDS Page 5083 Engine Controls - Error When Reprogramming ECU PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Error When Reprogramming ECU SPECIAL SERVICE TOOLS SS004-01 REVISED May 25, 2001 Title: ECU FLASH REPROGRAMMING ERROR MESSAGE Models: Applicable Models TSB REVISION NOTICE: September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded. Introduction During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message. Applicable Vehicles ^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles. ^ 2002 (and later) model year Camry, Solara and Tacoma vehicles. ^ 2003 (and later) model year Corolla and Matrix vehicles. ^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine) Required SSTs NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information Test Procedure Page 245 Page 2058 Mass Air Flow (MAF) Meter Electrical Specifications Resistance Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 2480 CHART 5 CHART 6 Page 6559 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 724 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR Resistance Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the crankshaft position sensor. Page 2911 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 557 CHART 14 Page 4839 5. As shown in the example chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Amount to turn adjusting cams (by graduation): Example: Front cam: 1.3 + Direction Rear cam: 3.3 + Direction d. Torque the front and/or rear adjusting cam set bolts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Page 5148 Glass - Windshield and Fixed Glass Bonding Windshield: Technical Service Bulletins Glass - Windshield and Fixed Glass Bonding COLLISION REPAIR INFORMATION CRIB127 TITLE: WINDSHIELD AND FIXED GLASS BONDING SECTION: EXTERIOR BULLETIN #127 MODELS: ALL TOYOTA & LEXUS DATE: MAY 2003 During windshield and fixed glass removal or replacement, it is crucial to follow proper installation procedures. These specific procedures are outlined in Toyota and Lexus model-specific repair manuals. The manuals provide detailed instructions and illustrations for removal and installation procedures for windshields, backlights and other fixed glass. Replacement Information The following recommendations are provided as supplemental in formation to model-specific Repair Manual documented procedures. ^ Technicians performing glass installations should be well trained andlor certified in glass installation methods. If training is needed, glass installation courses are available through I-CAR or through the National Glass Association (NGA). ^ Always inspect glass opening bonding surface for damage or corrosion that may negatively impact proper glass installation. ^ Consult manuals and disassemble as recommended for removal. ^ Cover interior and exterior panels and components to protect them from glass and bonding debris. ^ Remove glass making sure not to damage painted finishes. ^ Body filler materials should NOT be used on bond surfaces. ^ Apply a two-part epoxy primer to properly prepared bare metal on the bonding surface and allow to dry. ^ Test fit replacement glass. ^ Clean, prep, and prime glass as required by adhesive manufacturer. ^ Select proper urethane adhesive with an American National Standards Institute (ANSI) minimum lap-shear strength rating of 500-750 PSI. ^ Apply urethane bead to glass as specified (width and height) and set glass. ^ Vacuum or blow (with low pressure air) to clean debris from interior and air ducts and then re-assemble. Page 6973 Front Door (Part 2) Page 40 Daytime Running Lamp Relay: Testing and Inspection Terminal Identification Connector Disconnected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Connector Connected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Connect the wire harness side connector to the relay and inspect wire harness side connector from the back side, as shown. If circuit is not as specified, try replacing the relay with a new one. Page 1122 Driver Side J/B And Integration Relay Page 3607 1. REMOVE DETENT SPRING Remove the bolt, spring plate and detent spring. 2. REMOVE MANUAL VALVE 3. REMOVE PRESSURE RELEASE VALVE Remove the bolt, spring seat, spring and ball. 4. REMOVE SOLENOID VALVE a. Remove the 2 bolts and 3 solenoid valves. b. Turn the valve body, remove the bolt, lock plate and solenoid valve SLT. c. Remove the 3 O-rings from the 3 solenoid valves. Page 4297 A. Disconnect shock absorber from lower suspension arm. B. Remove the shock absorber lower side set nut and washer. NOTE: Do not remove the C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber. E. Remove the 3 nuts and shock absorber with the coil spring. NOTE: Do not damage the 8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint. Page 1922 CHART 15 Page 6205 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Locations Page 5609 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 6008 Symptom Related Diagnostic Procedures SRS Warning Light: Symptom Related Diagnostic Procedures SRS (Always Light Up, When Ignition Switch Is Lock Position.) SRS Warning Light Circuit Malfunction (Always lights up, when ignition switch is in LOCK position) 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 ACC or 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 E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS warning light. Wiring Diagram Page 5801 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 1033 Power Steering Fluid: Service and Repair BLEEDING 1. CHECK FLUID LEVEL 2. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3. TURN STEERING WHEEL With the engine stopped, turn the wheel slowly from lock to lock several times. 4. LOWER VEHICLE 5. START ENGINE Run the engine at idle for a few minutes. 6. TURN STEERING WHEEL a. With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 - 3 seconds, then turn the wheel to the opposite full lock position and keep it there for 2 - 3 seconds. b. Repeat a. several times. 7. STOP ENGINE 8. CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system. 9. CHECK FLUID LEVEL Page 3140 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Page 5608 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2046 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NO.1 1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO. 1 VEHICLE SPEED SENSOR Remove the bolt and No.1 vehicle speed sensor. 3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. 4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly. 5. INSTALL NO. 1 VEHICLE SPEED SENSOR Page 2295 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 6335 Clock: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 2096 Knock Sensor: Description and Operation P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION DTC Detection Condition One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block to detect the engine knocking. This sensor contains a piezoelectric element which generates voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking. If the engine knocking occurs, ignition timing is retarded to suppress it. Wiring Diagram Page 2752 CHART 2 CHART 3 CHART 4 Page 1886 Engine Bank Identification Page 3994 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection NOTE: This article contains corrected data processed from TSB# PG001-05. ABS ACTUATOR ON-VEHICLE INSPECTION 1. CONNECT TOYOTA HAND-HELD TESTER a. Connect the TOYOTA hand-held tester to the DLC3. b. Start the engine and run it at idle. c. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. HINT: Please refer to the TOYOTA hand-held tester operator's manual for further details. 2. INSPECT ABS ACTUATOR MOTOR OPERATION a. Check that the operation sound of the ABS actuator motor can be heard when the motor relay is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. If the operation sound cannot be heard, replace the ABS actuator because the motor operation is in failure. b. Turn the motor relay OFF. 3. INSPECT RIGHT FRONT WHEEL SOLENOID a. Depress the brake pedal and hold it for about 15 seconds, and check that the brake pedal does not go down further. If the brake pedal goes down, replace the ABS actuator because the sealing condition of the reduction solenoid valve is abnormal. b. Check that the brake pedal does not pulsate when the motor relay is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. If there is a pulsation in the brake pedal, replace the ABS actuator because the sealing condition of the reduction solenoid valve is abnormal. c. Turn the motor relay OFF. d. Depress the brake pedal and hold it until the step (g) is completed. e. Check that the brake pedal does not go down further when the SFRH solenoid is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep solenoid ON for more than 2 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. If the brake pedal goes down, replace the ABS actuator because the holding solenoid valve operation is abnormal. HINT: To prevent the solenoids, TOYOTA hand-held tester turns OFF automatically 2 secs. after has been turned ON simultaneously. f. Check that the brake pedal goes down further when the SFRR solenoid is turned ON by the TOYOTA hand-held tester. If the brake pedal does not go down, replace the ABS actuator because the reduction solenoid valve operation is abnormal. g. Check that the brake pedal returns when the motor relay is turned ON by the TOYOTA hand-held tester. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than Page 3484 Steps 1 - 2 Page 3751 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2079 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT 3. REMOVE LH NO.3 TIMING BELT COVER Page 1645 b. Apply seal packing to the sealing groove of water inlet housing as shown in the illustration. Seal packing: Part No. 08826-00100 or equivalent ^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening. ^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. ^ Immediately remove nozzle from the tube and reinstall cap. c. Install a new O-ring to the water inlet housing. d. Apply soapy water on the O-ring. e. Attach the water inlet housing end to the front water bypass joint hole. f. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) HINT: Each bolt length is indicated in the illustration. Bolt length: 76 mm (3.00 inch) for A 22 mm (0.87 inch) for B g. Connect the water bypass hose to the water inlet housing. 3. INSTALL NO.2 IDLER PULLEY 4. INSTALL TIMING BELT 5. FILL WITH ENGINE COOLANT 6. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 7. RECHECK ENGINE COOLANT LEVEL Page 1104 Engine Compartment Instrument Panel Locations Page 4811 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3662 1. CHECK DRIVE SHAFT a. Check to see that there is no remarkable play in the outboard joint. b. Check to see that the inboard joint slides smoothly in the thrust direction. c. Check to see that there is no remarkable play in the radial direction of the inboard joint. d. Check the boots for damage. 2. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS a. Using pliers, pinch the claws to compress the large inboard joint boot clamp and remove it. b. Using a side cutter, cut the small inboard joint boot clamp and remove it. c. Using a side cutter, cut the 2 outboard joint boot clamps and remove them. 3. REMOVE INBOARD JOINT SHAFT FROM OUTBOARD JOINT SHAFT a. Place matchmarks on the inboard and outboard joint shafts. NOTICE: Do not punch the marks. b. Using a snap ring expander, pull out the outboard joint shaft while expanding the snap ring. 4. REMOVE INBOARD AND OUTBOARD JOINT BOOTS 5. REMOVE DUST SEAL Using Special Service Tool (SST) and a press, remove the dust seal. SST 09950-00020 Page 3531 REMOVAL 1. REMOVE STEERING COLUMN ASSEMBLY Restraints - Seat Belt Tongue Plate Stopper Replacement Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Tongue Plate Stopper Replacement T-SB-0258-08 September 2, 2008 Seat Belt Tongue Plate Stopper Replacement Service Category Vehicle Interior Section Seat Belt Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. BO017-07. ^ Applicability has been updated to include 2008 model year vehicles. TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction For situations where only the seat belt stopper is broken a new service part has been developed to eliminate the need to replace the entire seat belt assembly. Follow the installation procedure below to utilize this new part. Page 3230 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 6813 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Collision / Non-Collision Inspections Clockspring Assembly / Spiral Cable: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION a. Do a diagnostic system check. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes b. Do a visual check which includes the following item with the steering wheel pad (with airbag) installed in the vehicle. Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a. Do a diagnostic system check. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. - Check cuts and cracks in wire harnesses, and chipping in connectors. - Check the deformation of the horn button contact plate on the steering wheel pad. HINT: If the horn button contact plate of the steering wheel pad is deformed, never repair it. Always replace the steering wheel pad with a new one. Page 3097 4. INSPECT THROTTLE POSITION SENSOR a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the throttle position sensor. c. Reconnect the throttle position sensor connector. 5. INSPECT ACCELERATOR PEDAL POSITION SENSOR a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F) If the resistance is not as specified, replace the accelerator pedal position sensor. c. Reconnect the pedal position sensor connector. 6. REINSTALL THROTTLE BODY COVER Body - Plastic Bumper Refinishing Front Bumper Cover / Fascia: Technical Service Bulletins Body - Plastic Bumper Refinishing TITLE: PLASTIC BUMPER REFINISHING SECTION: REFINISH BULLETIN # 170 MODELS: ALL TOYOTA LEXUS and SCION DATE: OCTOBER 2008 When it is necessary to replace a damaged plastic bumper, proper consideration should be given to preparation and refinishing to ensure high quality, long-term durability, and customer satisfaction. While it is important to follow paint manufacturer recommendations for application of refinish materials, this bulletin provides Toyota recommended procedures for cleaning and preparation of original equipment (OE) raw plastic bumpers. Background: Toyota bumper covers are manufactured using several types of plastic however, cleaning and preparation procedures outlined here are applicable to all Toyota, Lexus, and Scion raw plastic OE bumpers. Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile organic compound (VOC) emissions produced by the use of cleaning solvents. This topic is covered in Collision Repair Information Bulletin (CRIB) #69. Thorough cleaning with recommended soap and water removes soap-base mold release agent. Cleaning and Preparation: ^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap solution. Rinse well and dry with clean towels. Cleaning and Preparation, Continued^ Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic parts cleaner or water-base wax and grease remover, or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint manufacturer), with sanding paste and clean water. Repeat wash sequence, rinse well and dry with clean towels. ^ Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not appear to have been scuffed sufficiently. Repeat wash- rinse-dry sequence. ^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Apply anti-static measures. ^ Apply adhesion promoter per paint manufacturer7s recommendations. ^ Apply primer and topcoats per paint manufacturer7s recommendations. Note: Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to ensure adhesion, flexibility, and long-term durability of topcoats; and the use of refinish materials that meet or exceed the Toyota new vehicle limited paint finish warranty. Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer). This type of plastic requires the use of adhesion Recall - Rear Cross-Member Corrosion Technical Service Bulletin # SC90M Date: 091116 Page 1528 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications New gasket and the ECT sensor. Torque: .......................................................................................... .................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf) New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ............................................... .................................................................................................................................. 18 N.m (185 kgf.cm, 13 ft.lbf) Locations Vehicle Lift And Support Locations Page 1693 J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds. Then click Next. K. Turn ignition to the ON position. Then click Start. L. Do NOT disturb the vehicle during flash reprogramming. Page 630 CHART 23 Page 2477 O2S Application Table O2S Failure Threshold Charts Page 5240 3. INSPECT A/C SWITCH CONTINUITY If operation is not as specified, replace integration circuit bulb. 4. INSPECT A/C INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal A12 and negative (-) lead to A1. b. Push the A/C button in and check that the A/C indicator lights up. If operation is not as specified, replace the integration circuit. c. Connect the positive (+) lead from the battery to terminal A11 and negative (-) lead to terminal A10, then check that the indicator dimes. If operation is not as specified, replace the integration circuit. Page 2003 CHART 28 Diagrams Access Door Page 1500 Intake: N = T + (A - 0.20 mm (0.008 inch)) Page 4391 Parts Information NOTE: Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly. Page 2319 F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct. * NOTE: This screen displays the required version of Diagnostic Tester software that is compatible with the selected calibration file, and the other required steps to properly connect the Diagnostic Tester to your PC. ^ Type I calibration files are only compatible with software version 10.1a and older versions. ^ Type II calibration files are only compatible with software version 10.2a and newer versions. G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (Figure 10). Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED. H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic Tester Program Card. If there is insufficient Page 2204 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 226 Glossary Of Terms And Symbols (Part 2) Page 123 ^ Figure 17 shows an example of the update procedure for a two-processor ECU. G. Turn ignition OFF. Then click Next. H. Confirm the following: ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). ^ Hood is open. ^ All accessories are OFF. ^ Battery voltage is above 11.4 volts. NOTICE Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur. Page 4779 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2119 2. Tighten the union bolt by hand. 3. Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. Page 1689 When using Techstream Lite, select Generic J2534 Interface. Then click Next. E. Confirm the following: ^ PC is connected to VIM. ^ VIM is connected to DLC3 connector. ^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles). Page 3665 Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating REMOVAL 1. REMOVE REAR WHEEL 2. REMOVE BRAKE DRUM AND GASKET Page 1644 b. Check that the fluid coupling is not damaged and that no silicon oil leaks. If necessary, replace the fluid coupling. c. Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 5.4 Nm (55 kgf-cm, 47 inch lbs.) 3. INSPECT FAN PULLEY BRACKET Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket. 4. INSPECT TIMING BELT COMPONENTS INSTALLATION 1. INSTALL WATER PUMP a. Install a new O-ring to the water bypass pipe end. b. Apply soapy water to the O-ring. c. Connect the water pump to the water bypass pipe end. d. Install the water pump and a new gasket with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes. Torque: Bolt: 21 Nm (215 kgf-cm, 15 ft. lbs.) Stud bolt and nut: 18 Nm (185 kgf-cm, 13 ft. lbs.) 2. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and water pump. ^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. ^ Thoroughly clean all components to remove all the loose material. ^ Using a non-residue solvent, clean both sealing surfaces. Page 644 Oxygen Sensor: Mechanical Specifications Torque: Sensor 1 ................................................................................................................................. ............................................... 44 N.m (450 kgf.cm, 32 ft.lbf) Sensor 2 .............................................................................................................................................. .................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Page 118 NOTE Only Toyota Certified Technicians and above may access calibration files. 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON. B. Select Power Supply Mode by following the screen flow below. NOTICE ^ ECU damage may occur if the correct battery charger and mode setting are NOT used. Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminals and the switch body with the switch ON (switch pin released: opened door). b. Check that no continuity exists between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. Page 6811 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 2850 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 550 CHART 2 CHART 3 CHART 4 Capacity Specifications Steering - Lubricant Testing and Inspection Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the switch. Page 5238 Pinouts (Part 2) b. Connect the connector to A/C control assembly and inspect wire harness side from the back side, as shown in the chart. Test condition: Run engine at idle speed - Set on manifold gauge set If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Component Inspection AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration) INSPECTION Page 6011 Paint - Paint Colors Paint: Technical Service Bulletins Paint - Paint Colors PAINT PA001-02 May 31, 2002 Title PAINT COLORS Models All '01 - '02 Models & '03 Corolla & Matrix Introduction Attached for your reference is a list of OEM paint codes for all 2001 - 2002 model year vehicles and 2003 model year Corolla and Matrix vehicles. Note: The body color code is on the vehicle Certification Regulation Label, located on the left front door "B" pillar or door rear lower surface. Please contact your local paint representative for the actual paint mixing formulas or if you need help in color matching. Applicable Vehicles ^ 2001 - 2002 model year vehicles all models. ^ 2003 model year Corolla and Matrix vehicles. Warranty Information Paint Colors Page 2494 Page 28 Body Connector Location (Standard Cab) BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Seat Connector Location BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat) Page 977 A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015 and 09870-00025. - Made in USA - Fits both Toyota AC Clamps, used on high and low pressure lines. - Applicable to: 1998 and newer Toyota models - Stainless Steel release pins - Identification and Instructions are laser marked on the handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Testing and Inspection Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Four Wheel Drive Selector Relay; Testing and Inspection; Procedures. Page 2345 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Testing and Inspection Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Four Wheel Drive Selector Relay; Testing and Inspection; Procedures. Locations Relay Box: Locations Driver Side J/B And Integration Relay Page 6819 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1083 Glossary Of Terms And Symbols (Part 2) Page 1724 L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15). M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16). NOTE: With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat the above steps to reprogram a different vehicle needing the same calibration file. The steps above are only required when a new calibration file must be loaded onto the Diagnostic Tester Program Card. The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to reprogram the vehicle ECU. REPROGRAM ECU WITH TESTER 3. Reprogram the vehicle ECU with the Diagnostic Tester. NOTICE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below. ^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. ^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. ^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.). ^ Do not add to or significantly change the vehicle's electrical load while reprogramming. ^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F. Page 2965 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected f. SFI system wiring connectors fully plugged g. Ignition timing checked correctly h. Transmission in neutral position i. Air conditioning switched OFF 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Page 5025 Page 636 Page 6720 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * 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. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * 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 systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 6587 Splice Location I1 Cowl Wire I2 Cowl Wire I3 Cowl Wire I4 Cowl Wire I5 Cowl Wire I6 Cowl Wire I7 Engine Wire I8 Engine Wire I9 Engine Wire I10 Engine Wire I11 Engine Wire I12 Engine Wire I13 Engine Wire I14 Engine Wire I15 Engine Wire I16 Cowl Wire Body Splice Location (Access Cab) B1 Speaker Tweeter Wire LH B2 Front Door LH Wire B3 Front Door LH Wire B4 Roof Wire B5 Speaker Tweeter Wire RH B6 B7 Front Door RH Wire B8 Front Door RH Wire B9 Rear Door No. 1 Wire RH B10 Frame Wire Page 3964 5. INSPECT ACTUATOR OPERATION a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD -> 4HI position. b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI -> 2WD position. Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not as specified, replace the main sender gauge. INSPECT FUEL LEVEL WARNING SWITCH a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and check that the bulb lights up. HINT: It will take a short time for bulb to light up. b. Submerge the switch in fuel, and check that the bulb goes out. If operation is not as specified, replace the sender gauge. Page 1252 Exhaust Page 5714 Radio/Stereo: Splice Locations Engine Compartment Splice Location E1 Engine Room Main Wire E2 Engine Room Main Wire E3 Engine Room Main Wire E4 Engine No. 2 Wire E5 Engine Wire E6 Engine Wire E7 Engine Wire E8 Engine Wire Instrument Panel Page 2155 Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works in principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as an output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor, and controlled so that the potential of A and B remains equal in order to maintain the set temperature. Page 268 Airbag Sensor Assembly Page 3274 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 3. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated, carry out the adjustment procedure. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview 4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE VEHICLE Page 2898 Splice Point J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I5 is shaded. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. How to Read Connector List HOW TO READ CONNECTOR LIST A: Indicates connector to be connected to a part. (The numeral indicates the pin No.) Page 6207 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Testing and Inspection Air Bag Deactivation Indicator: Testing and Inspection INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 3031 Fuel Pump Ballast Resistor: Testing and Inspection FUEL PUMP RESISTOR INSPECTION 1. REMOVE FUEL PUMP RESISTOR 2. INSPECT FUEL PUMP RESISTOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.70 - 0.76 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the resistor. 3. REINSTALL FUEL PUMP RESISTOR Torque: 8 N.m (82 kgf.cm, 71 in.lbf) Page 2899 B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to wire harness from a different part.) Wire harness sharing the same short terminal grouping ha the same color. C: Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. D: Connector Color Connectors not indicated are milky white in color. How to Read Ground Points HOW TO READ GROUND POINTS Page 713 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard angle of the crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by the NE signal. Page 4331 1. REMOVE FRONT WHEEL 2. 4WD: REMOVE GREASE CAP Using a screwdriver and hammer remove the grease cap. 3. 4WD: DISCONNECT DRIVE SHAFT A. Remove the cotter pin and lock cap. B. While applying the brakes, remove the lock nut. 4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. 5. DISCONNECT BRAKE LINE Using the SST, disconnect the brake line. Use a container to catch the brake fluid. ^ 09023-00100 6. REMOVE BRAKE,CALIPER AND DISC Component Tests and General Diagnostics Brake Light Switch: Component Tests and General Diagnostics w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. w/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1788 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1860 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. REMOVE ENGINE UNDER COVER Diagram Information and Instructions Cruise Control: Diagram Information and Instructions Key to Diagrams A: System Title B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: 1 Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D: Indicates related system. Page 4132 Remove the 4 bolts and disconnect the lower ball joint. 9. REMOVE STEERING KNUCKLE A. Remove the cotter pin and loosen the nut. B. Using the following SSTs, disconnect the steering knuckle. ^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) C. Remove the nut and steering knuckle. NOTE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. 10. 2WD: REMOVE GREASE CAP A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the grease cap. HINT: Be careful not to damage the grease cap. 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). Page 4319 11. 4WD: REMOVE OIL SEAL (INSIDE) A. Mount the axle hub in a soft jaw vise. HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further. B. Using a screwdriver, remove the oil seal (inside). 12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen the staked part of the lock nut. NOTE: Be careful not to damage the bushing. A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010) NOTE: Do NOT use air wrench. B. Remove the ABS speed sensor rotor or spacer. NOTE: Take care not to scratch the serration of the speed sensor rotor. 13. REMOVE AXLE HUB FROM STEERING KNUCKLE A. Remove the 4 bolts and shift the dust cover toward the hub side (outside). B. Using the following SSTs, remove the axle hub from the steering knuckle. Page 3704 Drive/Propeller Shaft: Service and Repair REMOVAL 1. REMOVE FRONT PROPELLER SHAFT a. Place matchmarks on the differential and propeller shaft flange. b. Remove the 4 bolts, washers and nuts, disconnect the propeller shaft from the differential. Specifications Knock Sensor: Specifications SST 09816-30010 Torque: ................................................................................................................................................ ................................. 45 N.m (450 kgf.cm, 33 ft.lbf) Page 4385 Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut. Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf) 26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH NEW MOUNTING BOLTS A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.) B. Install the disc, brake caliper and 2 NEW bolts. Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf) C. Install the brake line clamp to the steering knuckle with the bolt. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 27. INSTALL NEW BRAKE LINE Using the SST, connect NEW brake line. ^ 09023-00100 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 29. 4WD: INSTALL DRIVE SHAFT LOCK NUT A. While applying the brakes, tighten the nut. Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf) B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 30. 2WD: INSTALL GREASE CAP 31. INSTALL FRONT WHEEL NOTE: Do NOT use air wrench. Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf) 32. DEPRESS BRAKE PEDAL SEVERAL TIMES 33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL) Page 6255 Body Connector Location (Access Cab) BA1 Front Door LH Wire and Wire Harness (Connector Location) BB1 Frame Wire and Cowl Wire (Under the Driver's Seat) BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH) BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat) BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel) BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel) BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel) BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel) BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat) Page 1850 Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf) b. Connect the ECT sensor connector. 8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) b. Connect the accelerator cable to the throttle body. 9. REINSTALL INTAKE AIR CONNECTOR 10. REFILL WITH ENGINE COOLANT 11. REINSTALL THROTTLE BODY COVER Service and Repair Fuel Pressure Release: Service and Repair SFI SYSTEM PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector. b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. Page 351 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY COVER 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold. c. Remove the gasket 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket and the ECT sensor. Component Locations Cruise Control System Page 5170 Page 2816 CHART 12 CHART 13 Page 6567 Seat Belt Reminder Lamp: Description and Operation KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the combination meter. This current activates the combination meter and the current flowing through the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL (A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds. Page 2824 CHART 22 Page 2307 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 5662 a. Install the front airbag sensors with the 4 bolts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) HINT: Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. NOTE: Connection of the connector is done after the sensor has been installed. - Make sure the sensor is installed with the specified torque. - If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with a new one. - The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. b. Connect the front airbag sensor connectors. c. Install the air cleaner assembly. d. 2UZ-FE engine: Install the battery tray, battery and battery carrier. Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: All Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle 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 operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 6086 Paint: Technical Service Bulletins Body - Acid Rain Paint Damage Prevention/Repair TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR SECTION: EXTERIOR BULLETIN # 165 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2008 Condition & Cause 'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric impurities, often referred to as industrial fallout. The mixing forms varying degrees of corrosive acidic compounds that can settle on exposed surfaces. Depending on geographic location, concentration level, and length of exposure; vehicle paint finish damage can occur. Horizontal surfaces such as roof, hood, and trunk panels are most vulnerable. Prevention of Finish Damage While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term durability, if not cared for properly they can sustain damage as a result of acid rain exposure. Exposure can occur at any time in the life-cycle of a vehicle, be it transport, storage, or consumer use. Dealers should refer to the Toyota Warranty Policy and Procedures Manual, Policy No.2.3 for information on Storage and Protection of New Vehicles. Detailed information is also provided on proper finish care in the Owner's Manual of all models. In brief, following washing and wax application recommendations should keep paint looking good. Inspection & Repair Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water spotting however, advanced stages of damage result in etching and depressions from the corrosive effect. Lightly rubbing a finger across a suspected acid rain stain may help to confirm etching. University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides detailed information on paint finish types, damage assessment methods, and repair techniques. And, Collision Repair & Refinish T101 and L101 'Paint Finish Repair' provide hands-on training. There is no substitute for a good training experience. Visit (www.crrtraining.com) for more information about hands-on training. Page 2537 load while reprogramming. ^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). ^ Confirm cable connections between the vehicle and Techstream are secure. ^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. ^ Set parking brake. ^ Complete ALL flash calibration updates provided for each ECU. ^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT "Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service bulletin. ^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools & Equipment - Battery Diagnostics. 3C. Click Next to start the calibration update process. D. When using TIS Techstream select Techstream VIM as the desired programming device. Then click Next. Page 6203 Glossary Of Terms And Symbols (Part 2) Page 5550 Page 3467 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5934 FOR SPECIAL SERVICE CAMPAIGN REAR FRAME CROSS MEMBER & LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION 2000-2003 MODEL YEAR TUNDRA