Toyota - Tacoma - Wiring Diagram - 2003 - 2003

Page 1017 J/B No.3 - Behind The Instrument Panel Center Page 491 Automatic Transmission Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Wiring Diagram Page 4070 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 852 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. 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 (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only the valves indicated in the illustration. 1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve Clearance (Cold) Capacity Specifications Fluid - A/T: Capacity Specifications Automatic transmission fluid A340E Dry fill ......................................................................................... ......................................................................................... 7.2 L (7.6 US qts, 6.3 Imp. qts) Drain and refill ...................................................................................................................................................... ............... 1.6 L (1.7 US qts, 1.4 Imp. qts) A340F Dry fill ..................................................................... ......................................................................................................... 10.1 L (10.7 US qts, 8.9 Imp. qts) Drain and refill .............................................................................................................................. ....................................... 2.0 L (2.1 US qts, 1.8 Imp. qts) Locations Locations El - Un 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 APPROX. 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 Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. Page 1015 J/B No.1 - Lower Finish Panel Page 2311 Locations ABS - Di Page 2867 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 4772 - 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. 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 airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. g. 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. Page 180 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 1505 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 8 Anti-lock Brake System Page 552 Page 3084 a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using 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/ spacer. 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 2337 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Page 4071 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 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 4760 - 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 INSPECT SUPPLEMENTAL RESTRAINT SYSTEM 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 pad. - Check the damage on the spiral cable connector and wire harness. 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. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Testing and Inspection/Initial Inspection and Diagnostic Overview Front Wheel Speed Sensor: Diagrams Front FRONT SPEED SENSOR REPLACEMENT W/ RELATED COMPONENTS Page 586 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Page 1293 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. 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. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Page 2297 CHART 15 Page 4487 3. 4WD: DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 5. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) c. Support the brake caliper securely. 6. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 4706 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 harness, 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 INSPECT SUPPLEMENTAL RESTRAINT SYSTEM 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. 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 70 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 2623 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Page 164 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. Locations Overdrive Switch: Locations Automatic Transmission Page 2728 Wiring Diagram Page 2206 Step 4 - 6 Page 436 Step 3 - 4 INSPECTION PROCEDURE Page 3561 2. Using SST, tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 N.m (173 kgf.cm, 13 ft.lbf) NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator. h. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. i. Reinstall the plunger, a new gasket, the end cover and lead clamp (1.8 kW) with the 3 bolts. Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf) for 1.4 kW 3.6 N.m (37 kgf.cm, 32 in.lbf) for 1.8 kW Page 3771 J/B No.3 Inner Circuit Page 3339 Brake Bleeding: Service and Repair 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. 3. BLEED BRAKE LINE a. Connect the vinyl tube to the caliper or wheel cylinder bleeder plug. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic. b. Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Page 3046 7. 3RZ-FE, 5VZ-FE w/ Diff. lock: REMOVE FRONT BEARING OUTER RACE AND OIL STORAGE RING a. Using SST, remove the front bearing outer race. SST 09308-00010 b. Using a screwdriver, bend the oil storage ring and remove it. 8. REMOVE BEARING SPACER a. 3RZ-FE, 5VZ-FE w/o Diff . lock: Remove the 2 washers. b. Remove the bearing spacer. 9. INSTALL NEW BEARING SPACER a. Install a new bearing spacer. b. 3RZ-FE, 5VZ-FE w/o Diff. lock Install the 2 washers. 10. 3RZ-FE, 5VZ-FE w/ Diff lock: INSTALL OIL STORAGE RING AND FRONT BEARING OUTER RACE a. Using SST and a hammer, install a new oil storage ring. SST 09316-60011 (09316-00011, 09316-00021) b. Using SST and a hammer, install the front bearing outer race. SST 09316-60011 (09316-00011, 09316-00021) 11. INSTALL FRONT BEARING a. Place the front bearing. b. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: Place the oil slinger. c. Using SST and the companion flange, install the front bearing then remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 12. INSTALL NEW OIL SEAL Page 2282 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 3797 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Page 1019 J/B No.1 Inner Circuit Page 2613 Throttle Body: Service and Repair w/o ECTS-I Throttle Body (w/o ETCS-i) THROTTLE BODY (w/o ETCS-I) REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT CABLES: a. W/ Cruise Control: Disconnect the cruise control actuator cable. Page 4558 3. REMOVE COOLING UNIT 4. REMOVE BLOWER UNIT a. Disconnect the connector from the blower motor. b. Disconnect the servomotor connector from the air inlet servomotor. c. Remove the nut, bolt and blower unit. INSTALLATION Installation is in the reverse order of removal. Page 843 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. 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. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Page 1048 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 2403 Leak Detection Solenoid: Testing and Inspection VSV For Pressure Switching Valve INSPECTION 1. REMOVE VSV 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. If there is no continuity, replace the VSV. 3. INSPECT 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. 4. INSPECT VSV OPERATION a. Check that air does not flow from ports E to F. Page 617 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 3593 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 3045 a. Using a chisel and hammer, loosen the staked part of the nut. b. Using SST to hold the flange, remove the nut. SST 09330-00021 c. Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 4. REMOVE OIL SEAL Using SST, remove the oil seal. SST 09350-32014 (09308-10010) 5. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: REMOVE OIL SLINGER 6. REMOVE FRONT BEARING Using SST, remove the front bearing from the drive pinion. SST 09556-22010 Page 855 Intake: N = T - (A - 0.18 mm (0.007 inch)) Page 4290 Part 2 Of 3 Page 2398 Engine Page 1548 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3612 J/B No.1 - Lower Finish Panel Testing and Inspection Dimmer Switch: Testing and Inspection w/o Tachometer (Resister Type): INSPECT LIGHT CONTROL RHEOSTAT a. Turn the rheostat knob OFF and check that no continuity exists between terminals (Rheostat knob turned to fully counterclockwise). b. Gradually, turn the rheostat knob from the dark side to bright side and check that the resistance decreases from 10 to 0 ohms (Rheostat knob turned to clockwise) If operation is not as specified, replace the rheostat. w/ Tachometer (Electrical Type): 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 and check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise and check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Page 1898 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 2299 CHART 18 CHART 19 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 3473 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Locations R/B No.2 - Engine Compartment Left Page 3503 b. Check the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. 4. INSPECT BRUSHES Using a scale, measure the exposed brush length. Standard exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes. 5. INSPECT RECTIFIERS (RECTIFIER HOLDER) a. Check the positive (+) rectifier. 1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. 2. Reverse the polarity of the tester probes and repeat step (a). 3. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. Page 173 ^ 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 2824 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 3787 Glossary Of Terms And Symbols Part 1 Page 2807 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 444 Bu - VSV (Double Cab) Page 4341 Page 509 Engine Page 252 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3540 Starter (Part 2) Page 1171 Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. 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 temperature sender gauge. Page 3909 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 794 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 4776 INSTALLATION 1. INSTALL SPIRAL CABLE 2. INSTALL UPPER AND LOWER COLUMN COVERS 3. INSTALL STEERING WHEEL 4. INSTALL STEERING WHEEL PAD Page 3759 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 Page 1058 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Locations Overdrive Switch: Locations Automatic Transmission Page 3319 5. CHECK DISC THICKNESS AND RUNOUT 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 the 2 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: 103 Nm (1,050 kgf-cm, 76 ft. lbs.) 10. DEPRESS BRAKE PEDAL SEVERAL TIMES 11. CHECK THAT FLUID LEVEL IS AT MAX LINE Page 1375 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19mm deep socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 2242 Engine Page 3523 El - Un Page 4741 Air Bag Control Module: Service and Repair 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 FRONT CONSOLE BOX Page 1315 Part 2 Of 3 Page 2474 a. Temporarily install the inlet pipe with 2 new gaskets, union bolt and bolt. b. Tighten the clamp bolt Torque: 8 N.m (80 kgf.cm, 71 in.lbf) c. Tighten the union bolt. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 5. INSTALL FUEL PRESSURE REGULATOR 6. INSPECT AIR ASSIST LINES AND CONNECTIONS Visually check for loose connections, sharp bends or damage. 7. INSTALL INTAKE AIR CONNECTOR ASSEMBLY 8. INSTALL AIR CLEANER HOSE 9. CHECK FOR FUEL LEAKS FUEL SYSTEM a. 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 911 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the "LOW" and "FULL" lines. When the engine is cold. If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the "FULL" line. DO NOT FURTHER DILUTE PRE-MIXED MANUFACTURER APPROVED ETHYLENE GLYCOL BASED COOLANT IF USED. MIX ACCORDING TO THE MANUFACTURER'S DIRECTIONS. 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 water outlet filler hole, and the coolant should be free from oil. If they are excessively dirty, clean the coolant passages and replace the coolant. c. Reinstall the radiator cap. Page 3575 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 2803 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 94 J/B No.3 - Behind The Instrument Panel Center Page 961 - 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 2025 Applicable Vehicles Page 938 c. Connect SST, as shown. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check that the valve of the SST is in the open position. d. Bleed the power steering system. e. Start the engine and run it at idle. f. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) g. With the engine idling, close the valve of the SST and observe serve 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. h. With the engine idling, open the valve fully. i. 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. Testing and Inspection Horn Switch: Testing and Inspection INSPECT HORN SWITCH a. Check that no continuity exists between the horn contact plate and body ground. b. Check that continuity exists between the horn contact plate and body ground when the horn contact plate is pressed against the steering spoke assembly. If continuity is not as specified, repair or replace the steering wheel or wire harness as necessary. Page 4423 Stabilizer Bar: Service and Repair REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE FRONT WHEELS Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE STABILIZER BAR LINKS a. Remove the 2 nuts and stabilizer bar link from the lower suspension arm and stabilizer. Torque: 90 Nm (920 kgf-cm, 66 ft. lbs.) HINT: If the ball joint stud turns together with the nut, use a hexagon wrench to hold the stud. b. Employ the same manner described above to the other side. 3. REMOVE STABILIZER BAR Component Locations Wire Harness And Connector Page 3952 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Page 3260 Anti-lock Brake System Specifications Intake Manifold: Specifications Intake manifold vacuum at idle speed .................................................................................................................................................. 60 kPa (450 mm Hg, 17.7 inch Hg) or more Intake manifold Warpage maximum ............................................................................................................................................. .................................... 0.10 mm (0.0039 inch) Intake manifold, Intake manifold stay x Cylinder head ........................................................................................................ 18 Nm (180 kgf-cm, 13 ft. lbs.) Intake air connector x Intake manifold ................................................................................................................................. 18 Nm (180 kgf-cm, 13 ft. lbs.) Page 1010 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 4237 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 II or III HINT: Check that the fluid level is within the HOT LEVEL range on the 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. 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE Engine: Loosen the 3 bolts and air cleaner assembly. b. Disconnect the pressure feed tube from the PS vane pump. Page 585 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Specifications Valve Clearance: Specifications Valve clearance at cold Intake ................................................................................................................................................... ................ 0.13 - 0.23 mm (0.006 - 0.009 inch) Exhaust ..................................................................... ........................................................................................... 0.27 - 0.37 mm (0.011 - 0.014 inch) Page 2483 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Part 1 Page 660 Knock Sensor Part 1 Testing and Inspection Leak Detection Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. HINT: Near the fuel tank. 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. Connect a voltmeter to terminals PTNK and E2, and measure the output voltage. Voltage: 3.0 - 3.6 V Page 4815 ABS - Di Air-Fuel Ratio (A/F) Sensor Oxygen Sensor: Testing and Inspection Air-Fuel Ratio (A/F) Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT If the resistance is not as specified, replace the sensor Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 4077 J/B No.1 Inner Circuit Page 2849 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. Specifications Compression Check: Specifications Compression pressure at 250 rpm STD .......................................................................................................................................................... 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum .......................................................................... ..................................................................................... 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder ......................................................................................................... 100 kPa (1.0 kgf/cm2, 15 psi) or less Page 3586 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 1806 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: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e. If the cylinder compression in 1 or more cylinders is low, pour a 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, it is likely 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 2722 Bu - VSV (Except Double Cab) Page 2116 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 2806 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 2183 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. Capacity Specifications Engine Oil: Capacity Specifications Capacity 2WD Drain and refill W/ Oil filter change .............................................................................................................................................................. 5.9 L (6.2 US qts, 5.2 Imp. qts) W/o oil filter change ............................................................................................................................................................. 5.1 L (5.4 US qts, 4.5 Imp. qts) Dry fill ................................................................................................. ................................................................................. 6.3 L (6.7 US qts, 5.5 Imp. qts) 4WD Drain and refill W/ oil filter change ....................................................................................................................... ........................................ 5.2 L (5.5 US qts, 4.6 Imp. qts) W/o Oil filter change ............................................................................................................................................................ 4.9 L (5.2 US qts, 4.3 Imp. qts) Dry fill ................................................................................................. ................................................................................. 5.9 L (6.2 US qts, 5.2 Imp. qts) Page 2382 VSV For Evaporative Emission (EVAP) Page 1515 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 873 NOTICE: Always turn the crankshaft clockwise. b. Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. c. Remove the crankshaft pulley bolt. 11. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. 12. INSTALL NO.1 TIMING BELT COVER AND STARTER WIRE BRACKET a. Check that the timing belt cover gaskets have cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. 1. Using a screwdriver and gasket scraper, remove all the old gasket material. 2. Thoroughly clean all components to remove all the loose material. 3. Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded back in the illustration. b. Install the timing belt cover with the 4 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c. Install the starter wire bracket with the 2 bolts. 13. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the pulley, and slide the pulley. b. Using SST, install a new bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 295 Nm (3,000 kgf-cm, 217 ft. lbs.) Removal and Installation Wheel Hub: Service and Repair Removal and Installation Part 1 Of 2 Page 3243 Automatic Transmission Page 1200 Engine Oil: Fluid Type Specifications Grade ................................................................................................................................ API SH, Energy-Conserving II or ILSAC multigrade engine oil. Viscosity ......................................................... ............................................................................................................................................................ 5W-30 Page 4128 J/B No.3 Inner Circuit Page 3010 ^ 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." Page 1362 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 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 2861 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 3777 Engine Compartment Instrument Panel Locations Page 2276 Page 2708 Spark Plug: Application and ID Recommended Spark Plug DENSO made ...................................................................................................................................... .............................................................. K16TR11 NGK made ........................................................................................................................................... ...................................................... BKR5EKB-11 Page 1040 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2594 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Page 2354 Engine Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Page 767 Driver's Switch Front Passenger's Switch (Window Unlock) Front Passenger's Switch (Window lock) Rear Left Switch (Window Unlock) Page 2796 ^ 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 2189 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 4208 Camber: -0°10' (-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: -(Shorter) 2.9 Rear cam: -(Shorter) 2.7 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) 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 HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less Page 3021 Bu - VSV (Except Double Cab) Page 4339 Page 112 ^ 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 759 Bu - VSV (Except Double Cab) Page 3366 2. REMOVE LSP & BV ASSEMBLY a. Using SST, disconnect the brake lines from the valve body. SST 09023-00100 b. 2WD (except pre runner): Remove the clip from the flexible hose bracket. c. 2WD (except pre runner): Remove the 3 valve bracket mounting bolts and spacer, and remove the LSP & BV assembly. d. 4WD and pre runner: Remove the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt, and remove the LSP & BV assembly and flexible hose bracket. INSTALLATION 1. INSTALL LSP & BV ASSEMBLY TO FRAME a. 2WD (except pre runner): Install the 3 valve bracket mounting bolts and spacer with the LSP & BV assembly. b. 4WD and pre runner: Install the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt with the LSP & BV assembly and flexible hose bracket. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) 2. CONNECT BRAKE LINE Using SST, connect the brake lines. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) SST 09023-00100 3. CONNECT SHACKLE NO. 2 TO SHACKLE BRACKET a. Install the shackle No. 2 to the shackle No. 1 with the 2 nuts. b. Set dimension A. Initial set c. Tighten the lock nut. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Install the shackle No. 2 with the 2 cushions and collar to the shackle bracket. e. Install the nut to fix the cushion retainer. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) 4. SET REAR AXLE LOAD Page 3789 Relay Box: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 1974 Page 2990 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Locations Fusible Link: Locations R/B No.2 - Engine Compartment Left Page 234 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3647 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 2491 CAUTION: - Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45014 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3 (See step 1). h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. 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 fuel hose connections, fuel pump, fuel filter and fuel pressure regulator k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kgf/sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. Page 1837 Engine Page 81 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Locations Intake Air Temperature Sensor: Locations Engine Testing and Inspection Heater Core: Testing and Inspection HEATER RADIATOR INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air. Page 1639 CHART 5 CHART 6 Testing and Inspection Torque Converter Clutch: Testing and Inspection TORQUE CONVERTER CLUTCH AND DRIVE PLATE 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 (09351-32010 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 clutch and retest the clutch. Replace the converter clutch if the clutch still fails the test. 2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator, measure drive plate runout. Maximum runout: 0.20 mm (0.0079 inch) If runout is not within the specification, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tight the bolts. Torque: 3RZ-FE: 74 Nm (750 kgf-cm, 54 ft. lbs.) 5VZ-FE: 83 Nm (850 kgf-cm, 61 ft. lbs.) Page 2498 Engine 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, side airbag assembly, airbag sensor assembly, front airbag sensor side airbag sensor assembly or door side 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 2271 Page 2106 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 3645 Page 3289 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB REMOVE SPEED SENSOR a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. ^ The sensor is installed flat against the axle end when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 3667 J/B No.3 Inner Circuit Page 3845 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Page 4601 10. INSPECT MODE SWITCH CONTINUITY Check the continuity between terminals at each switch position as shown in the chart. If continuity is not as specified, replace the switch. Page 19 Step 3 INSPECTION PROCEDURE Page 3305 Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbs.): More than 105 mm (4.13 inch) If the reserve distance is incorrect, troubleshoot the brake system. Page 2100 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 4074 J/B No.3 - Behind The Instrument Panel Left Page 3145 El - Un Recall 05V225000: Front Lower Ball Joint Replacement Ball Joint: All Technical Service Bulletins Recall 05V225000: Front Lower Ball Joint Replacement MAKE/MODELS: Model/Build Years: Toyota/4 Runner 2001-2002 Toyota/Sequoia 2002-2004 Toyota/Tacoma 2001-2004 Toyota/Tundra 2002-2004 MANUFACTURER: Toyota Motor North America, Inc. NHTSA CAMPAIGN ID NUMBER: 05V225000 RECALL DATE: May 06, 2005 COMPONENT: Suspension: Front: Control Arm: Lower Ball Joint POTENTIAL NUMBER OF UNITS AFFECTED: 774856 SUMMARY: On certain sport utility vehicles, due to a manufacturing issue in the front suspension lower ball joint, there is a possibility that the surface of the ball of the joint may have been scratched. The ball joint may eventually experience excessive wear and looseness, resulting in increased steering effort. CONSEQUENCE: The lower ball joint may separate from the knuckle causing loss of steering control and a crash could occur with prior warning. REMEDY: Dealers will replace the front suspension lower ball joints. The recall is expected to begin on July 15, 2005. Owners should contact Toyota at 1-800-331-4331. NOTES: Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. 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 1373 Automatic Transmission 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 1686 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Page 1313 Part 3 Of 3 WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Page 4200 Alignment: Specifications Front wheel Alignment ^ Vehicle height RZN161L-TRMDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -43 mm (-1.69 inch) Heavy duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -40 mm (-1.57 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -41 mm (-1.61 inch) RZN161L-TRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -43 mm (-1.69 inch) Heavy-duty leaf spring Tire size: P255/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ............................................................................................................... -40 mm (-1.57 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -41 mm (-1.61 inch) VZN170L-CRMDKAB Normal Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/75R15 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -44 mm (-1.73 inch) Tire size: P265/75R15 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -45 mm (-1.77 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 53 mm (2.10 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111S Rear: C*3 - D*4 .................................................................................................................................... ....................................... -39 mm (-1.54 inch) Tire size: P265/70R16 111T Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ............................................................................................................... -38 mm (-1.50 inch) VZN170L-CRPDKAB Normal Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -44 mm (-1.73 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -45 mm (-1.77 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 49 mm (1.93 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.64 inch) Heavy-duty leaf spring Tire size: P225/75R16 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -38 mm (-1.50 inch) Tire size: P265/70R16 111S Page 3556 a. Remove the 2 screws. Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) for 1.4 kW 9.3 N.m (95 kgf.cm, 82 in.lbf) for 1.8 kW b. Remove the starter housing, return spring, the clutch assembly, idler gear and bearing from the magnetic switch assembly. 3. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. 4. REMOVE BRUSH HOLDER a. Remove the 2 screws end frame from the field frame. Page 549 Locations Id - Wi Page 1889 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 931 Engine Oil: 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: API grade SL Energy-Conserving or ILSAC multi-grade engine oil. 2. CHECK ENGINE OIL LEVEL After warming up the engine and then 5 minutes after the engine stop, the oil level should be between the low level and full level marks on the dipstick. If low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 3. REMOVE OIL PRESSURE SWITCH Using SST, remove the oil pressure switch. SST 09268-06021 4. INSTALL OIL PRESSURE GAUGE 5. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 6. CHECK OIL PRESSURE Oil pressure 7. REMOVE OIL PRESSURE GAUGE Page 689 Bu - VSV (Except Double Cab) 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 Page 4039 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. 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 the wire routing is shown in square brackets [ ]. 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 1650 Page 3526 Ignition 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. Page 1050 Step 1 Page 2294 CHART 11 Page 4710 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. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. 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. - Regular cab, Extra cab: Check for cuts and cracks in, or marked discoloration on the quarter trim. - Double cab: Check for cuts and cracks in, or marked discoloration on the center pillar and quarter trim. - Check for cuts and cracks in wire harness, and for chipping in connectors. - Regular cab, Extra cab: Check for deformation of the quarter panel. - Double cab: Check for deformation of the center pillar. - Check for cuts minute cracks in wire harness or marked discoloration on the front seat outer belt. 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. - Regular cab, Extra cab: Check for deformation of the quarter panel. - Double cab: Check for deformation of the center pillar. - 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 SEAT BELT WITH PRETENTIONER In the following cases, replace the seat belt with pretentioner. - Seat belt pretensioner has been activated. - Seat belt pretensioner has been found to be faulty in troubleshooting. - Front seat outer belt has been found to be faulty in test. - 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 882 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2RZ-FE and 3RZ-FE: 5VZ-FE: 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY L3CK NUT TEMPORALLY Torque: 2.5 N.m (25 kgf.cm, 22 in..lbf) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 + 25 lbf Used belt: 100 + 25 lbf 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Page 3281 Bu - VSV (Double Cab) Page 1520 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 1116 Wheel Fastener: Service and Repair Rear REPLACEMENT 1. REMOVE REAR WHEEL AND BRAKE DRUM 2. REMOVE REAR HUB BOLT Using SST and a brass bar or an equivalent, remove the hub bolt. SST 09650-17011 3. 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. 4. INSTALL BRAKE DRUM AND REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 2285 Page 977 J/B No.1 - Lower Finish Panel Details Page 812 r. Stop the engine. s. 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. t. 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 u. Remove the other union bolt 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks 3. INSPECT FUEL PUMP RESISTANCE a. Pull up the LH rear seat cushion. b. Remove the floor service hole cover with the 3 screws. c. Disconnect the fuel pump connector. d. Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 0.3 Ohm at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or set plate. 4. INSPECT FUEL PUMP OPERATION a. Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operations. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. Page 2619 Engine Page 4121 Relay Box: Connector Views J/B No.1 - Lower Finish Panel Page 937 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 II or III HINT: Check that the fluid level is within the HOT LEVEL range on the 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. 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE Engine: Loosen the 3 bolts and air cleaner assembly. b. Disconnect the pressure feed tube from the PS vane pump. Page 62 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2123 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 3149 El - Un Page 4019 BU1 Page 3535 Step 2 - 3 Page 1912 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 Page 1746 Engine Page 418 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. Page 3913 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 4055 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 118 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 2816 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 3629 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Locations Transmission Mode Switch: Locations Automatic Transmission Page 4750 Supplemental Restraint System Page 1759 Engine Page 3565 Engine Specifications Connecting Rod Bearing: Specifications Connecting rod bearing center wall thickness Reference Mark 1 ......................................................................................................................................................... 1.484 - 1.488 mm (0.0584 - 0.0586 inch) Mark 2 ......................................................................................................................................................... 1.488 - 1.492 mm (0.0586 - 0.0587 inch) Mark 3 ......................................................................................................................................................... 1.492 - 1.496 mm (0.0587 - 0.0589 inch) Locations ABS - Di Page 597 Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor -- Go to Powertrain Management Diagrams. Specifications Brake Caliper: Specifications Front disc brake caliper x Flexible hose ............................................................................................................................... 30 Nm (310 kgf-cm, 22 ft. lbs.) Testing and Inspection Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kOhm per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Specifications Page 2804 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 1498 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 3924 R/B No.2 Part-2 Engine Room Fuse Details J/B No.1 Part-1 Page 3994 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Cruise Control System (w/ETCS-i) Neutral Safety Switch: Testing and Inspection Cruise Control System (w/ETCS-i) Park/Neutral Position Switch Circuit (A/T) CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECM. When this signal is input during the cruise control driving, the ECM cancels the cruise control. Wiring Diagram Step 1 Page 3630 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 1614 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 3047 a. Coat a new oil seal lip with MP grease. b. 2RZ-FE: Using SST and a hammer, install the oil seal, SST 09554-30011 Oil seal drive in depth: 1.5 mm (0.059 inch) c. 3RZ-FE, 5VZ-FE w/o Diff. lock: 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 Oil seal drive in depth: 0.5 mm (0.020 inch) HINT: Connect SST with vinyl tape. d. 3RZ-FE, 5VZ-FE w/ Diff lock: Using SST and a hammer, install the oil seal. SST 09214-76011 Oil seal drive in depth: 1.0 mm (0.039 inch) 13. 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: 2RZ-FE: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 3RZ-FE, 5VZ-FE w/o Diff. lock: 147 Nm (1,500 kgf-cm, 109 ft. lbs.) 3RZ-FE, 5VZ-FE w/ Diff. lock: 196 Nm (2,000 kgf-cm, 145 ft. lbs.) 14. ADJUST DRIVE PINION PRELOAD Page 3511 b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. c. Install the 4 nuts. Torque: 4.5 N.m (45 kgf.cm, 39 in.lbf) 3. INSTALL PULLEY 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. As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C). e. To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110 N.m (1,125 kgf.cm, 81 ft.lbf) f. Remove the generator with SST (A) and (B) from SST (C). g. Turn SST (B) and remove SST (A) and (B). 4. INSTALL RECTIFIER HOLDER Page 3545 c. Using vernier calipers, measure the commutator diameter. Standard diameter Minimum diameter If the diameter is less than minimum, replace the armature. d. 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. 3. INSPECT FIELD COIL Locations Instrument Panel Page 4407 7. REMOVE NO. 1 AND NO. 2 SPRING BUMPERS Using SST, remove the No. 1 and No. 2 spring bumpers. SST 09922-10010 Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.) HINT: At the time of installation, use a torque wrench with a fulcrum length of 345 mm (13.58 inch). INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment. Page 1479 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 3631 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 3266 Electronic Brake Control Module: Testing and Inspection Terminals Of ECU / Pinouts Part 1 Page 3407 A/C - Ho Page 705 Ignition 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. Page 1887 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 1005 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Page 4299 Part 2 Of 3 Page 1516 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 3957 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 4163 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. Page 4114 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 1745 Engine Page 3602 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 Page 2041 Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM 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. Page 151 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 540 CHART 8 CHART 9 Locations Air Flow Meter/Sensor: Locations Engine Page 4567 Blower Motor Resistor: Testing and Inspection BLOWER RESISTOR INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS 2. REMOVE BLOWER RESISTOR a. Disconnect the resister connector from the blower resistor. b. Remove the 2 screws and blower resistor. 3. INSPECT BLOWER RESISTOR RESISTANCE If resistance is not as specified, replace the blower resistor. 4. INSTALL BLOWER RESISTOR a. Install the blower resistor with the 2 screws. b. Connect the resister connector to the blower resistor. 5. INSTALL GLOVE COMPARTMENT PARTS Page 116 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 1172 HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Page 3731 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. 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 the wire routing is shown in square brackets [ ]. 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 3617 J/B No.1 Part-2 Page 3313 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 Diagrams Oil Cooler: Diagrams OIL COOLER REPLACEMENT W/ RELATED COMPONENTS Page 259 ABS - Di Page 1392 Part 2 Of 3 Page 1049 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 745 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 3560 e. Temporarily install these new terminal C kit parts: 1. Terminal insulator (inside) NOTE: Be careful to Install the terminal insulator (inside) in the correct direction. 2. Contact plate 3. Terminal bolt 4. O-ring 5. Terminal insulator (outside) 6. Wave washer 7. Terminal nut f. Temporarily tighten the terminal nuts. g. Tighten the 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. - 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. Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 70 liter tank 60 liter tank If resistance value is not as specified, replace the sender gauge. 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 and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 741 El - Un w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 2817 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 213 El - Un Page 1298 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: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e. If the cylinder compression in 1 or more cylinders is low, pour a 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, it is likely 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 117 ^ 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 w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 Exploded Views Generator Page 1854 Engine Page 3080 3. 4WD: DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 5. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) c. Support the brake caliper securely. 6. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) Page 1541 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 645 Engine Page 4734 Air Bag Control Module: Locations Airbag Sensor Assembly Page 542 CHART 11 Page 3110 c. Install the 2 removed bearing outer races to the spider. d. Using SST, push out the bearing from the yoke. SST 09332-25010 e. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. 5. SELECT SPIDER BEARING Select the bearing according to whether or not there is a drill mark on the yoke section. 6. INSTALL SPIDER BEARING a. Apply MP grease to a new spider and bearings. NOTICE: Be careful not to apply too much grease. b. Align the matchmarks on the yoke and shaft. c. Fit the spider into the yoke. Page 1064 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 Page 1247 NOTICE: Always turn the crankshaft clockwise. b. Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. c. Remove the crankshaft pulley bolt. 11. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. 12. INSTALL NO.1 TIMING BELT COVER AND STARTER WIRE BRACKET a. Check that the timing belt cover gaskets have cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. 1. Using a screwdriver and gasket scraper, remove all the old gasket material. 2. Thoroughly clean all components to remove all the loose material. 3. Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded back in the illustration. b. Install the timing belt cover with the 4 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c. Install the starter wire bracket with the 2 bolts. 13. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the pulley, and slide the pulley. b. Using SST, install a new bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 295 Nm (3,000 kgf-cm, 217 ft. lbs.) Page 76 Page 2141 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. Locations Fuse: Locations R/B No.2 - Engine Compartment Left Page 3478 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 Specifications Brake Bleeding: Specifications Fluid Type AE J1703 or FMVSS No.116 DOT3 Page 1012 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. Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT 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 226 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 4193 With the customer accompanying you, drive the vehicle to confirm if the customer's complaint involves vehicle pulling to one side or steering wheel off center. If the problem is steering wheel off center, refer to the Repair Manual for the adjustment procedure. For 2002 model year vehicles only, refer to TSB No. ST003-01, "Steering Wheel Off Center Adjustment Procedure". Also check the direction of vehicle pulling and the extent of pulling. C. Decide if vehicle pulling is due to wheel alignment or tires. (1) Switch the left and right front tires (If the tires are non-unidirectional). (2) Conduct a drive test to check whether the direction that the vehicle pulls has changed. Helpful hints to determine cause of vehicle pulling: ^ The direction of lateral force from tire conicity becomes reversed when the left and right tires are switched. Therefore if the pulling direction changes when the tires are switched it can be concluded that vehicle pulling is caused by tire conicity. ^ The vehicle is pulled to the right by the lateral force exerted to the right. ^ The direction of the tires which exerted lateral force to the right has been changed, so the tires now exert lateral force to the left and the vehicle now pulls to the left. ^ If the pulling direction does not change after the front tires are switched the cause of vehicle pulling is not tire conicity. In this case the likely cause is a front wheel alignment condition. 2. Vehicle Pulling Caused by Wheel Alignment. Page 483 Camshaft Position Sensor Front Wheel Speed Sensor: Diagrams Front FRONT SPEED SENSOR REPLACEMENT W/ RELATED COMPONENTS Page 2233 Engine Page 4111 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 4127 J/B No.3 Inner Circuit Page 3175 Automatic Transmission Specifications Valve Clearance: Specifications Valve clearance at cold Intake ................................................................................................................................................... ................ 0.13 - 0.23 mm (0.006 - 0.009 inch) Exhaust ..................................................................... ........................................................................................... 0.27 - 0.37 mm (0.011 - 0.014 inch) 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 1006 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Page 2265 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 1919 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 2844 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 791 By performing this operation, it can be checked whether the left or right tire exerts a stronger lateral force. Either tire can be reversed. Shown here is an example of the left tire reversed. If Vehicle Pull Is Eliminated: Repair Is Now Complete. The lateral force generated by the left and right front tires is virtually the same so the lateral force is neutralized and the vehicle travels straight ahead. The repair operation is now completed. B. Rotate the larger lateral force front tire with the rear tire and check the change in the vehicle pulling. NOTE By shifting the front tire with the larger lateral force to the rear, the vehicle pulling level is usually reduced. If Vehicle Is Still Pulling: Go to step 3C. If Vehicle Pull Is Eliminated: Repair Is Now Complete. C. Adjust cross camber to eliminate vehicle pulling. HINT If the tires are placed in the positions they were in during tire rotation when the least amount of vehicle pulling occurred, wheel alignment can be performed with a minimal amount of adjustment. NOTE ^ Keep the cross camber within 10 or less. ^ Keep the camber of each wheel within specifications (+/-45' of center value). ^ If adjustment exceeds the specifications, uneven tire wear will result. 4. Camber Adjustment Method. ^ After the camber has been adjusted, inspect the toe-in. Page 2059 Page 998 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Locations Knock Sensor: Locations Id - Wi Page 2275 Applicable Vehicles Page 1755 Ignition 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. Page 528 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 539 CHART 7 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 1629 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 2960 Automatic Transmission Page 2138 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 1842 4. REINSTALL NO.2 TIMING BELT COVER Page 4283 Body Control System Page 2114 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 1578 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 2470 Fuel Injector: Service and Repair Injector Part 1 Page 3654 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned on, battery positive voltage is applied to terminal IGSW of the ECM and the EFI main relay (Marking: EFI) control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI main relay. This signal causes current to flow to the coil, closing the contacts of the EFI, main relay and supplying power to terminals +B of the ECM. w/o ETCS: If the ignition switch is turned off, the ECM continues to switch on the EFI main relay for a maximum of 2 seconds for the initial setting of the IAC valve. Wiring Diagram Page 2597 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Page 2032 Engine Bank Identification Page 1364 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 3700 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Page 482 Engine Page 204 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 661 Knock Sensor Part 2 Page 4726 Wire Harness And Connector Page 1466 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 1740 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Page 562 CHART 28 Page 2390 Engine Page 3370 a. Install the load sensing valve boot and load sensing spring boot. b. Install the 2 rubber plates, 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 a. Install the lock nut washer and shackle No. 1 to the shackle No. 2. b. Torque the 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 the shackle No. 1. b. Install the bolt 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. 2WD (except pre runner): Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts with flexible hose bracket. b. 4WD and pre runner: Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts. c. Install the bolt and nut with the 2 plate washers. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB REMOVE SPEED SENSOR a. Disconnect the speed sensor connector. b. Remove the 2 (4WD and pre runner) or 4 (2WD (except pre runner)) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm, steering knuckle: 8.0 Nm (82 kgf-cm, 71 inch lbs.) Side rail: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. ^ The sensor is installed flat against the knuckle when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation Is in the reverse order of removal. NOTICE: After Installation, check the speed sensor signal. Page 3608 Diagram Legend Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. Connector Views: The connector views for connectors referred to within these diagrams can be found at the Vehicle level Connector Views. Page 2044 CHART 2 CHART 3 CHART 4 Page 309 Power Door Lock Switch: Testing and Inspection Master switch (2 door): INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 983 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 86 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 Page 346 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB REMOVE SPEED SENSOR a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. ^ The sensor is installed flat against the axle end when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 1554 Engine Page 4773 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 airbag 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. 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. Page 2389 Engine Page 1920 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 997 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 265 2. REMOVE LOWER CENTER COVER 3. Double cab: DISCONNECT REAR HEATER DUCTS Remove the 2 bolts and disconnect the LH and RH rear heater ducts. 4. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the 3 connectors. NOTE: Remove the connector with the sensor assembly installed. b. Remove the bolt holding the No.1 brace to the floor. c. Using a torx wrench, remove the 3 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace 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 the 3 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) b. Remove the bolt holding the No.1 brace to the floor. c. Connect the 3 connectors. NOTE: Installation of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed to 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. Page 3382 4. DISCONNECT BRAKE LINES Using SST, disconnect the 3 brake lines and remove the brake line from the master cylinder and 3-way. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 5. REMOVE MASTER CYLINDER Remove the 2 nuts, wire harness bracket, 3-way, check valve bracket and master cylinder. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: ^ Before installation, adjust the length of the brake booster push rod. ^ After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. ^ Check and adjust the brake pedal. Page 1988 Step 6(Continued) - 8 Step 9 INSPECTION PROCEDURE Page 4579 Compressor And Magnetic Clutch REMOVAL 1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES WITH A/C ON 2. STOP ENGINE 3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY 4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 5. REMOVE ENGINE UNDER COVER 6. 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. REMOVE COMPRESSOR a. Remove the fan shroud. b. Loosen the drive belt. c. Remove the compressor mounting bolts and the compressor. 8. REMOVE COMPRESSOR BRACKET a. 2RZ-FE, 3RZ-FE Engine: Remove the 4 bolts and compressor bracket. b. 5VZ-FE Engine: Remove the 5 bolts and compressor bracket. INSTALLATION 1. INSTALL COMPRESSOR BRACKET a. 2RZ-FE, 3RZ-FE Engine: Install the bracket with 4 bolts. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) b. 5VZ-FE Engine: Install the bracket with 5 bolts. Torque: 47 N.m (475 kgf.cm, 34 ft.lbf) Locations Transmission Mode Switch: Locations Automatic Transmission Page 2077 Oxygen Sensor: Service Precautions MAINTENANCE PRECAUTIONS Precautions when the handling oxygen sensors. 1. Do not allow oxygen sensor to drop or hit against an object. 2. Do not allow the sensor to come into contact with water. Page 2165 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 526 A/F and 02 Sensor Identification Page 3067 a. Using a brass bar and hammer, remove the hub bolts, oil deflector and gasket. b. Position a new gasket on the axle shaft and install a washer and nut to a new hub bolt, as shown in the illustration, and install the hub bolt by torquing the nut. 10. INSTALL REAR AXLE SHAFT IN BACKING PLATE a. Coat a new 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. 11. 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) 12. REPLACE OIL SEAL (INNER SIDE) a. Using SST remove the oil seal. SST 09308-00010 Diagrams Power Steering Pump: Diagrams Part 1 Of 2 Diagrams Wheel Hub: Diagrams Part 1 Of 2 Page 308 Bu - VSV (Except Double Cab) Page 1975 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 4142 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. w/ ECTS-I Throttle Body: Service and Repair w/ ECTS-I Throttle Body (w/ETCS-i) THROTTLE BODY (w/ ETCS-I) REMOVAL 1. DRAIN ENGINE COOLANT Page 4057 Page 4248 3. CONNECT PRESSURE FEED TUBE a. Install the union bolt with a new gasket on each side of the tube. Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.) HINT: Make sure the stopper of the tube is touching the PS pump body as shown, then torque the union bolt. b. Install the oil pressure switch to the pressure feed tube. Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.) c. Connect the connector to the oil pressure switch. 4. CONNECT RETURN HOSE 5. INSTALL AIR CLEANER ASSEMBLY Install the air cleaner assembly with the 3 bolts. 6. BLEED POWER STEERING SYSTEM Page 3697 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. 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 Locations Switch: Locations A/C - Ho Page 3860 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Service and Repair 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. Locations Transmission Temperature Sensor/Switch: Locations A/C - Ho Page 68 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 2485 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. Attach the pressure regulator to the LH delivery pipe. c. Check that the pressure regulator rotates smoothly. NOTE: If it does not rotate smoothly, the O-ring may be pinched, so remove the pressure regulator and repeat steps (a) to (c) above. d. Install the pressure regulator with the 2 bolts. Torque: 8 N.m (80 kgf.cm, 71 in.lbf) e. Install the engine wire with the bolt. 2. CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR NOTE: Be sure to insert the hose up to the stopper and clip it. 3. INSTALL INTAKE AIR CONNECTOR ASSEMBLY 4. INSTALL AIR CLEANER HOSE 5. CHECK FOR FUEL LEAKS Page 4782 Supplemental Restraint System Page 933 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. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil dipstick. c. Remove the oil drain plug and drain the oil into a container. 2. REPLACE OIL FILTER a. Using SST, remove the oil filter (located on left side of the cylinder block) SST 09228-07501 b. Clean the filter contact surface on the filter mounting c. Apply clean engine oil to the gasket of a new oil filter d. Tighten the filter by hand until the gasket contacts the seat of the filter mounting. Then using SST, give it an additional 3/4 turn to seat the filter. SST 09228-07501 3. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. b. Fill the engine with new oil. Oil capacity c. Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE LEVEL Locations Transmission Control System Relay: Locations Instrument Panel Page 2920 Wiring Diagram Page 2834 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. Removal and Installation Heater Core Case: Service and Repair Removal and Installation Heater Unit (Part 1) Page 1526 Engine Control Module: Locations Instrument Panel Page 251 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 4302 5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS a. Using a screwdriver and hammer, unstake the washer. NOTICE: Avoid any impact to the steering rack. b. Using a spanner to hold the steering rack steady, and using SST, remove the rack end. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. c. Remove the claw washer. d. Employ the same manner described above to the other side. HINT: Mark the RH and LH rack ends. 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the rack guide spring cap lock nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. 7. REMOVE RACK GUIDE SPRING CAP 8. REMOVE RACK GUIDE SPRING, RACK GUIDE AND RACK GUIDE SEAT 9. REMOVE DUST COVER Page 3267 Terminals Of ECU / Pinouts Part 2 Locations A/C - Ho Page 1347 Heater Core: Service and Repair HEATER RADIATOR REMOVAL 1. REMOVE HEATER UNIT 2. REMOVE HEATER RADIATOR a. Remove the 5 screws and 2 plates and clamp. b. Pull out the heater radiator. c. Remove the 2 screws and 2 clips then disconnect the heater radiator pipes. HINT: At the time of reassembly please refer to the following item. Do not reuse 2 O-rings. INSTALLATION Installation is in the reverse order of removal. Page 3905 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 1026 J/B No.1 - Lower Finish Panel Details Page 3508 Alternator: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE REAR END COVER a. Remove the nut and terminal insulator. b. Remove the 3 nuts and end cover. 2. REMOVE BRUSH HOLDER a. Remove the 2 screws, brush holder and cover. b. Remove the brush holder cover from the brush holder. 3. REMOVE VOLTAGE REGULATOR Remove the 3 screws and voltage regulator. 4. REMOVE RECTIFIER HOLDER Page 4472 Vehicle Lift And Support Locations Part 2 Page 3579 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 440 ABS - Di Page 2517 Fuel Tank And Line Page 1723 Engine Page 3009 Continuously Variable 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. Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Page 4716 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Page 4078 J/B No.3 Inner Circuit Page 1956 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 3141 Terminals Of ECM/Pinouts Part 1 Terminals Of ECM/Pinouts Part 2 Page 477 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Capacity Specifications Coolant: Capacity Specifications Fluid capacity M/T ...................................................................................................................................................... ........................... 9.7 L (10.3 US qts, 8.5 Imp. qts) A/T ....................................................................... .......................................................................................................... 9.5 L (10.0 US qts, 8.4 Imp. qts) Page 3649 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 3888 Abbreviations Page 1849 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19mm deep socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. 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 4576 Compressor Clutch: Testing and Inspection COMPRESSOR AND MAGNETIC CLUTCH ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. START ENGINE 3. CHECK METALLIC SOUND OF COMPRESSOR Check if there is an abnormal metallic sound from the compressor when the A/C switch is on. If abnormal metallic sound is heard, replace the compressor assembly. 4. CHECK REFRIGERANT PRESSURE 5. STOP ENGINE 6. CHECK REFRIGERANT LEAK OF 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 GREASE LEAK OF CLUTCH BEARING 9. CHECK SIGN OF OIL ON PRESSURE PLATE If necessary, repair or replace. 10. CHECK NOISE OF MAGNETIC CLUTCH BEARING 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. 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. Locations Fuse Block: Locations R/B No.2 - Engine Compartment Left Page 198 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 3401 Vacuum Brake Booster: Service and Repair REMOVAL 1. REMOVE MASTER CYLINDER 2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3. REMOVE PEDAL RETURN SPRING 4. REMOVE CLIP AND CLEVIS PIN 5. REMOVE BRAKE BOOSTER a. Remove the clevis from the push rod. b. Remove the 4 booster installation nuts. c. Remove the booster and gasket. d. 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 a new gasket and the booster with the 4 nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Install the clevis to the operating rod. e. Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. f. Connect the vacuum hose to the brake booster. 2. ADJUST LENGTH OF BOOSTER PUSH ROD Page 214 Engine Control Module (ECM) Locations Id - Wi Page 1957 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 2701 Knock Sensor Part 2 Page 4060 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 1312 Part 2 Of 3 Page 4203 Tire size: P265/70R16 111T .............................................................................................................................................. 1°37' ± 45' (1.61° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................... 1°41'± 45' (1.69° ± 0.75°) Tire size: P265/70R16 111S .............................................................................................................................................. 1°43' ± 45' (1.71° ± 0.75°) Tire size: P265/70R16 111T .............................................................................................................................................. 1°41' ± 45' (1.68° ± 0.75°) RZN161L-TRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°37' ± 45' (1.62° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°38' ± 45' (1.64° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°37' ± 45' (1.61° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°42' ± 45' (1.70° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°43' ± 45' (1.71° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°41' ± 45' (1.69° ± 0.75°) VZN170L-CRMDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°42' ± 45' (1.70° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°43' ± 45' (1.72° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°41' ± 45' (1.69° ± 0.75°) Off-road package ................................................................................................... ............................................................. 2°02' ± 45' (2.03° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°50' ± 45' (1.83° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°51' ± 45' (1.85° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°49' ± 45' (1.82° ± 0.75°) VZN170L-PRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................... 2°36'± 45'(2.60° ± 0.75°) Tire size: P265/70R16 111S .............................................................................................................................................. 2°36'± 45' (2.61° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 2°35' ± 45' (2.59° ± 0.75°) Off-road package .............................................................................................................................................................. 2°39' ± 45' (2.66 ° ± 0.75°) VZN171L-CRMDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°44' ± 45' (1.74° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°45' ± 45' (1.75° ± 0.75°) Tire size: P265/70R16 111T ........................................................................................................................................... 1°44' ± 45' (1.73 ° ± 0.75 °) Off-road package ...................................................................................................... ......................................................... 2°02' ± 45' (2.03° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R16 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°52' ± 45' (1.87° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................ 1 °51' ± 45' (1.85° ± 0.75°) RZN171L-CRPDKAB Normal Tire size: P225/75R15 102S, P265/70R16 111S .............................................................................................................................................................. 1°44'± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°45' ± 45' (1.75° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R16 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°52' ± 45' (1.87° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°51' ± 45' (1.85° ± 0.75°) RZN191L-TRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°37' ± 45' (1.62° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°38' ± 45' (1.63° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°37' ± 45' (1.61° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°43' ± 45' (1.72° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°44' ± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................ 1°43' ± 45' (1.71° ± 0.75°) VZN195L-CRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................ 1°43' ± 45' (1.71° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°44' ± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T .............................................................................................................................................. 1°42'± 45' (1.70° ± 0.75°) Off-road package ................................................................................................... ............................................................ 1°56' ± 45' (1.93° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) 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 3130 Step 5 INSPECTION PROCEDURE Page 1698 Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor -- Go to Powertrain Management Diagrams. Page 3030 Bu - VSV (Double Cab) Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Page 3806 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 4209 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. 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, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). Page 1638 CHART 2 CHART 3 CHART 4 Page 4340 Page 1201 Engine Oil: 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: API grade SL Energy-Conserving or ILSAC multi-grade engine oil. 2. CHECK ENGINE OIL LEVEL After warming up the engine and then 5 minutes after the engine stop, the oil level should be between the low level and full level marks on the dipstick. If low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 3. REMOVE OIL PRESSURE SWITCH Using SST, remove the oil pressure switch. SST 09268-06021 4. INSTALL OIL PRESSURE GAUGE 5. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 6. CHECK OIL PRESSURE Oil pressure 7. REMOVE OIL PRESSURE GAUGE Page 1950 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 3213 El - Un Page 183 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. Specifications Idle Speed: Specifications Idle speed ............................................................................................................................................ ............................................................. 700 ± 50 rpm Component Tests and General Diagnostics Air Bag Control Module: Component Tests and General Diagnostics Collision / Non-Collision Inspections 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION AND SRS IS NOT DEPLOYED Do a diagnostic system check. * 3. VEHICLES INVOLVED IN COLLISION AND SRS IS 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/Initial Inspection and Diagnostic Overview Replacement Requirements REPLACEMENT 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: Be sure to follow the correct procedure, for removal and installation of the airbag sensor assembly. Locations Three-way Catalytic Converter (TWC) System Cruise Control System (w/ETCS-i) Cruise Control System (w/ETCS-i) 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 712 Step 4 INSPECTION PROCEDURE Page 2038 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 2053 CHART 16 CHART 17 Page 995 Step 1 Page 4396 Part 2 Of 2 REMOVAL REMOVE STEERING KNUCKLE WITH AXLE HUB HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB INSPECTION INSPECT UPPER BALL JOINT FOR ROTATION CONDITION Page 3048 15. STAKE DRIVE PINION NUT 16. CONNECT REAR PROPELLER SHAFT 2WD 17. 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 80W - 90 Capacity Page 789 With the customer accompanying you, drive the vehicle to confirm if the customer's complaint involves vehicle pulling to one side or steering wheel off center. If the problem is steering wheel off center, refer to the Repair Manual for the adjustment procedure. For 2002 model year vehicles only, refer to TSB No. ST003-01, "Steering Wheel Off Center Adjustment Procedure". Also check the direction of vehicle pulling and the extent of pulling. C. Decide if vehicle pulling is due to wheel alignment or tires. (1) Switch the left and right front tires (If the tires are non-unidirectional). (2) Conduct a drive test to check whether the direction that the vehicle pulls has changed. Helpful hints to determine cause of vehicle pulling: ^ The direction of lateral force from tire conicity becomes reversed when the left and right tires are switched. Therefore if the pulling direction changes when the tires are switched it can be concluded that vehicle pulling is caused by tire conicity. ^ The vehicle is pulled to the right by the lateral force exerted to the right. ^ The direction of the tires which exerted lateral force to the right has been changed, so the tires now exert lateral force to the left and the vehicle now pulls to the left. ^ If the pulling direction does not change after the front tires are switched the cause of vehicle pulling is not tire conicity. In this case the likely cause is a front wheel alignment condition. 2. Vehicle Pulling Caused by Wheel Alignment. Page 2644 4. REINSTALL NO.2 TIMING BELT COVER Page 1640 CHART 7 Front Wheel Fastener: Service and Repair Front REPLACEMENT HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC 3. REMOVE HUB BOLT Using SST, 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 hammer handle or an equivalent to hold, install the bolt by torquing the nut. 5. INSTALL BRAKE DISC AND CALIPER 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 7. DEPRESS BRAKE PEDAL SEVERAL TIMES Page 2216 Engine Locations A/C - Ho Page 3367 5. SET VALVE BODY a. When pulling down the load sensing spring, confirm that the valve piston moves down smoothly. b. Position the valve body so that the valve piston lightly contacts the load sensing spring. c. Tighten the valve body mounting nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) 6. BLEED BRAKE LINE 7. CHECK AND ADJUST LSP & BV FLUID PRESSURE Page 1825 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 124 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 644 Engine Page 981 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. 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 the wire routing is shown in square brackets [ ]. 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 2614 b. Disconnect the accelerator cable. c. A/T: Disconnect the throttle cable. 3. REMOVE AIR CLEANER HOSE 4. REMOVE THROTTLE BODY a. Disconnect the throttle position sensor connector. b. Disconnect the IAC valve connector. c. Disconnect the vacuum hose for the throttle opener. d. Disconnect the water bypass hose (from water bypass pipe). e. Disconnect the water hose (from intake manifold). f. Disconnect the air assist hose. g. Remove the 2 bolts, 2 nuts, throttle body and gasket. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) HINT: At the time of installation, please refer to the following items. Place a new gasket on the air intake chamber facing the protrusion upward. INSTALLATION Installation is in the reverse order of removal. INSPECTION 1. CLEAN THROTTLE BODY Page 3703 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 4021 BN7 - BR2 (Double Cab) Page 3374 Hydraulic Control Assembly - Antilock Brakes: Service and Repair REMOVAL 1. DISCONNECT CONNECTOR 2. DISCONNECT BRAKE LINES Page 1490 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 2289 CHART 2 CHART 3 CHART 4 Locations Switch: Locations A/C - Ho Page 1991 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 919 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. NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. Page 2162 ^ 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 3068 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 Installation is in the reverse order of removal. HINT: After installation, bleed the brake system and check the ABS speed sensor signal. Page 4342 Page 98 J/B No.3 Inner Circuit Page 612 Engine Page 505 Engine The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 1167 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. 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 (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only the valves indicated in the illustration. 1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve Clearance (Cold) Page 3633 Abbreviations Page 2291 CHART 7 Page 2190 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 4430 1. REPLACE FRONT EYE BUSHING Using SST and a press, replace the bushing. SST 09550-10013 (09252-10010, 09553-10010) HINT: When installing the bushing, as shown in the illustration. 2. REPLACE REAR EYE BUSHINGS a. Using a saw, cut the both bushing tabs as shown in the illustration. b. Using 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. Page 275 Engine Page 3029 El - Un Page 1043 Glossary Of Terms And Symbols Part 1 Page 638 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 1074 J/B No.1 Inner Circuit Page 3997 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Page 1517 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 3769 J/B No.1 Inner Circuit Page 3112 DANA made b. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. 8. CHECK SPIDER BEARING a. Check that the spider bearing moves smoothly. Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 70 liter tank 60 liter tank If resistance value is not as specified, replace the sender gauge. 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 and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 2707 Spark Plug: Specifications Torque Torque Spark Plug Torque 13 ft.lbf Page 1394 Water Pump: Service and Repair Part 1 Of 3 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. Locations Acceleration/Deceleration Sensor: Locations ABS - Di Page 2667 Engine Page 1042 Abbreviations Page 2472 CAUTION: Catch leaking fuel in a container. 5. REMOVE FUEL PIPE 6. DISCONNECT INJECTOR CONNECTORS 7. REMOVE DELIVERY PIPES AND INJECTORS NOTE: 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 4 bolts and delivery pipes together with the 6 injectors. b. Remove the 4 spacers from the Intake manifold. c. Pull out the 6 injectors from the delivery pipes. d. Remove the 2 O-rings and insulator from each injector. INSTALLATION 1. INSTALL INJECTORS AND DELIVERY PIPES a. Install a new insulator to each injector. b. Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector. c. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors. d. Position the injector connector outward. Page 4631 Evaporator Temperature Sensor / Switch: Service and Repair THERMISTOR REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE THERMISTOR a. Disconnect the connector clamp. b. Pull out the thermistor from evaporator. INSTALLATION Installation is in the reverse order of removal. Page 481 Engine Testing and Inspection 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 belt has chunks missing from the ribs, it should be replaced. b. Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Boroughs 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 616 Engine Specifications Brake Drum: Specifications Rear brake drum inside diameter STD ..................................................................................................................................................... ........................................ 295.0 mm (11.614 inch) Maximum ............................................................. ........................................................................................................................ 297.0 mm (11.693 inch) Rear brake drum to shoe clearance ........................................................................................................................................................ 0.6 mm (0.024 inch) Rear drum brake wheel cylinder x Backing plate ................................................................................................................... 10 Nm (100 kgf-cm, 7 ft. lbs.) Page 1820 Engine Specifications Brake Fluid: Specifications Brake fluid type ......................................................................................................................................................... SAE J1703 or FMVSS No.116 DOT3 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 1324 Coolant: Fluid Type Specifications Coolant type: In order to avoid technical problems, only use "Toyota Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. Follow the manufacturers dilution recommendations on the label. 1. Do not use alcohol type antifreeze or plain water alone. 2. DO NOT FURTHER DILUTE PRE-MIXED MANUFACTURER APPROVED ETHYLENE GLYCOL BASED COOLANT IF USED. Specifications Tires: Specifications Cold tire inflation pressure P205/75R1597S Front .................................................................................................................................................... .......................... 200 kPa (2.0 kgf/cm2, 29 psi) Rear .......................................................................... ..................................................................................................... 200 kPa (2.0 kgf/cm2, 29 psi) P235/55R1696T Front .................................................................................................................................................... .......................... 200 kPa (2.0 kgf/cm2, 29 psi) Rear .......................................................................... ..................................................................................................... 220 kPa (2.2 kgf/cm2, 32 psi) P225/75R15102S Front .................................................................................................................................................... .......................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear .......................................................................... ..................................................................................................... 200 kPa (2.0 kgf/cm2, 29 psi) P265/70R16111S Front .................................................................................................................................................... .......................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear .......................................................................... ..................................................................................................... 180 kPa (1.8 kgf/cm2, 26 psi) P265/70R16111T Except double cab models Front .................................................................................................................................................... .................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear ................................................................................ ......................................................................................... 200 kPa (2.0 kgf/cm2, 29 psi) Double cab models Front .................................................................................................................................................... .................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear ................................................................................ ........................................................................................ 180 kPa (1. 8 kgf/cm2, 26 psi) Page 3536 Step 4 INSPECTION PROCEDURE Page 3805 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft pulley x Crankshaft ...................................................................................................................................... 250 Nm (2500 kgf-cm, 184 ft. lbs.) Page 3802 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Page 2193 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. Page 3996 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 1599 Engine Check Steering Wheel Free Play and Effort Steering Wheel: Testing and Inspection Check Steering Wheel Free Play and Effort INSPECTION 1. CHECK STEERING WHEEL FREEPLAY 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. Reference: 4.9 Nm (50 kgf-cm, 43 inch lbs.) HINT: Be sure to consider the tire type, pressure and contact surface 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 3613 J/B No.1 - Lower Finish Panel Details Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Page 4101 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 3641 Step 1 Page 4052 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 1747 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Page 3053 El - Un Vehicle Lift and Support Locations (Double Cab) Vehicle Lifting: Locations Vehicle Lift and Support Locations (Double Cab) Vehicle Lift and Support Locations Page 2450 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 1899 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 3548 Minimum spring installed load If the installed load is less than minimum, replace the brush springs. 7. INSPECT BRUSH HOLDER Check the 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. 8. INSPECT CLUTCH AND GEAR a. Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the ring gear of the flywheel/drive plate for wear or damage. b. Check the clutch pinion gear. Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks. If necessary, replace the clutch assembly. 9. INSPECT MAGNETIC SWITCH a. Check the pull-in coil for open circuit. 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 1810 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. 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 (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only the valves indicated in the illustration. 1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve Clearance (Cold) Page 2194 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. Locations Fusible Link: Locations R/B No.2 - Engine Compartment Left Page 1124 Vehicle Lifting: Locations Vehicle Lift and Support Locations (Except Double Cab) Vehicle Lift And Support Locations Part 1 Page 1653 Page 3953 Locations Shift Interlock Relay: Locations Instrument Panel Page 2218 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 4157 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Page 4384 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 3482 ^ 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". Locations R/B No.2 - Engine Compartment Left Locations Transmission Temperature Sensor/Switch: Locations A/C - Ho Page 3744 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 2465 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 4253 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 following rotor and cam ring marks: 3. INSPECT FLOW CONTROL VALVE 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 392 - 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. Page 4606 Heater Control Assembly (Part 2) REMOVAL 1. REMOVE CENTER LOWER COVER Page 1433 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 2006 Engine Locations P23 - P24 Page 2159 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 714 Step 2 - 3 Locations Key Reminder Switch: Locations Ignition Switch And Key Unlock Warning Switch Page 1202 8. REINSTALL OIL PRESSURE SWITCH a. Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST, install the oil pressure switch. SST 09268-06021 Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 9. START ENGINE AND CHECK FOR LEAKS Page 1317 a. Remove the 4 nuts and fan from the fluid coupling. 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: 7.4 Nm (75 kgf-cm, 65 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. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block. 1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. 2. Thoroughly clean all components to remove all the loose material. 3. Using a non-residue solvent, clean both sealing surfaces. b. Apply seal packing to the water pump groove 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 the water pump with the 7 bolts. Page 3304 Brake Pedal Assy: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK PEDAL HEIGHT Pedal height from dash panel: 154 - 168 mm (6.06 - 6.61 inch) NOTICE: Do not adjust the pedal height. Doing so by changing the push rod length of the brake booster will structurally change the pedal ration. If the pedal height is incorrect, check that there is no damage in brake pedal, brake pedal lever, brake pedal bracket and dash panel. ^ Even if there is damage, there is no problem if the reserve distance is within the standard value. ^ If necessary, replace the brake pedal, brake pedal lever, brake pedal bracket or brake pedal assembly. 2. 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: 1.0 - 2.4 mm (0.039 - 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. 3. CHECK PEDAL RESERVE DISTANCE Release the parking brake. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster, measure the pedal reserve distance, as shown. Page 4313 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). c. Using a brass bar and hammer, stake the claw washer. NOTICE: Avoid any impact to the rack. d. Employ the same manner described above to the other side. 14. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS a. Ensure that the steering rack hole is not clogged with grease. HINT: If the steering rack hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. Page 1246 c. Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d. Install the timing belt to the No.2 idler pulley. e. Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f. Install the timing belt to the water pump pulley. g. Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h. Install the timing belt to the No.1 idler pulley. 8. SET TIMING BELT TENSIONER a. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 200 - 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 tensioner. 9. INSTALL TIMING BELT TENSIONER a. Temporarily install the tensioner with the 2 bolts. b. Alternately tighten the 2 bolts. Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.) c. Remove the 1.27 mm hexagon wrench from the tensioner. 10. CHECK VALVE TIMING a. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. Page 1499 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 1862 Engine Page 3970 J/B No.3 - Behind The Instrument Panel Left Page 1271 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. A/C switch is OFF. 2. CONNECT HAND-HELD TESTER OR OBD II SCAN TOOL a. Connect the hand-held tester or OBD II scan tool to the DLC3. b. Please refer to the hand-held tester or OBD II scan tool operator's manual for further details. 3. INSPECT IDLE SPEED a. Race the engine speed at 1,000 rpm for approximately 5 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT HAND-HELD TESTER OR OBD II SCAN TOOL Page 3688 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 4391 Ball Joint: Testing and Inspection FRONT LOWER BALL JOINT ON-VEHICLE INSPECTION HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 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 lbs.). Maximum: 0.5 mm (0.020 inch) Page 2243 Automatic Transmission Page 2301 Page 959 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: 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 Locations Throttle Position Sensor: Locations Id - Wi Page 4441 c. Remove the 3 retainers, 2 cushions, suspension support and coil spring. INSPECTION INSPECT SHOCK ABSORBER 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. REPLACEMENT 1. REMOVE BUSHING Using SST and a press, remove the bushing. SST 09506-35010, 09632-36010 2. INSTALL NEW BUSHING Using SST and a press, install a new bushing. Page 4730 Air Bag Harness: Service and Repair REPLACEMENT In the following cases, replace the wire harness or connector. - If any part of the SRS wire harness or any connector has been found to be faulty in troubleshooting. - If any part of the SRS wire harness or any connector has been found to be faulty during checking items. NOTE: If the wire harness used in the SRS is damaged, replace the whole wire harness assembly. Page 4097 Relay Box: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 404 Bu - VSV (Double Cab) Page 939 j. 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. k. Disconnect the SST. l. Connect the pressure feed tube. m. 5VZ-FE Engine: Install the air cleaner and 3 bolts. n. Bleed the power steering system. Page 4011 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 554 Page 211 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 4282 El - Un Page 2234 Engine Page 596 Automatic Transmission Page 4751 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-off switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the passenger airbag is disabled, OFF indicator inside the switch will light up. Page 518 Applicable Vehicles 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 4819 Terminals Of ECU /pinouts Capacity Specifications Fluid - Differential: Capacity Specifications Rear With Short Wheel Base With Rear differential Lock System .............................................................................................................................................. 2.65 Liters (2.8 US qt.) Without Rear differential Lock System .......................................................................................................................................... 2.55 Liters (2.7 US qt.) With Extra Long Wheel Base With Rear differential Lock System ............................................................................................................................................... 2.95 Liters (3.1 US qt.) Without Rear differential Lock System ........................................................................................................................................... 2.45 Liters (2.6 US qt.) Recall 03V146000: Fuel Hose Protector Installation Fuel Return Line: Recalls Recall 03V146000: Fuel Hose Protector Installation DEFECT: On certain double cab pickup trucks, during side impact NCAP testing, a flange at the rear end of the double cab body deformed and contacted the fuel inlet hose that connects the fuel filler pipe and fuel tank, resulting in damage to the fuel inlet hose. This damage could result in fuel leakage, which could result in a fire in the presence of an ignition source. REMEDY: Dealers will install a fuel hose protector on the body flange. The manufacturer has reported that owner notification is expected to begin during June 2003. Owners may contact Toyota at 1-800-331-4331. Page 1384 Thermostat: Pressure, Vacuum and Temperature Specifications Valve opening temperature .............................................................................................................................................................. 80 - 84°C (176 - 183°F) Page 2945 El - Un Page 1439 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 4511 If operations are not as specified, replace the servomotor. 4. INSTALL AIR OUTLET SERVOMOTOR a. Install the servomotor with the 3 screws. b. Connect the servomotor connector. 5. INSTALL LOWER LH FINISH PANEL Page 560 CHART 27 Page 893 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 3062 Axle Shaft: Service and Repair Part 1 Of 2 Specifications Front Airbag Sensor Page 4469 Vehicle Lifting: Locations Vehicle Lift and Support Locations (Except Double Cab) Vehicle Lift And Support Locations Part 1 Page 1353 Radiator: Service and Repair Removal and Installation REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE 3. DISCONNECT UPPER RADIATOR HOSE 4. DISCONNECT RADIATOR RESERVOIR HOSE 5. DISCONNECT LOWER RADIATOR HOSE 6. REMOVE RADIATOR NO.2 FAN SHROUD 7. A/T: DISCONNECT OIL COOLER HOSES 8. REMOVE RADIATOR Remove the 4 bolts and the radiator. Torque: 12 Nm (120 kgf-cm, 8.7 ft. lbs.) HINT: Insert the tabs of the radiator support through the radiator service holes. INSTALLATION Installation is in the reverse order of removal. Locations Transmission Control System Relay: Locations Instrument Panel Page 4207 a. Loosen the front and/or rear adjusting cam nuts. 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. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10' (0.17°) Caster: 1°40' (1.67°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Page 2237 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Page 4774 Clockspring Assembly / Spiral Cable: Service and Repair Airbag Assembly Connectors DISCONNECTION a. Place a finger on the slider. b. Slide the slider to release lock. c. Disconnect the connector. CONNECTION a. Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. b. 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 the click can be heard at the time of fitting in.). HINT: As the slider slides, do not touch it. - Be careful not to deform the release board. If the release board is deformed, replace it with a new one. Page 1302 Valve Clearance: Adjustments INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. 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 (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a. Check only the valves indicated in the illustration. 1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2. Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve Clearance (Cold) Page 2007 Engine Page 3999 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Page 3294 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 1924 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 358 Automatic Transmission Page 45 Tail Lamp Relay: Testing and Inspection INSPECT TAILLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2651 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 3546 a. Check the 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. b. 1.4 kW: Check the field coil for ground. 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. 4. 1.8 kW: INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between terminal (A) and (B). Standard resistance: 1.4 - 1.9 ohms at 20 °C (68 °F) If the resistance is not as specified, repair or replace the field frame. Page 3819 J/B No.3 Inner Circuit Page 2209 Terminals Of ECM/ Pinouts Part 2 Page 2184 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 Evaporative Vapor Pressure Sensor: Locations Bu - VSV (Double Cab) Page 1878 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 2567 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 2108 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. Electrical - SRS And HV Wiring Repairs Wiring Harness: All 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 414 El - Un Page 4456 Part 2 Of 2 REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 2467 Injector Part 2 Page 2121 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 3800 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 69 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Page 2949 El - Un Page 1861 Engine Page 4699 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE a. Disconnect the pressure switch connector. b. Remove the pressure switch and O-ring. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mounted 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 the switch. INSTALLATION Installation is in the reverse order of removal. Page 3594 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 2764 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 1906 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. Locations Id - Wi Page 75 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Page 2361 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Page 277 Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY (Marking: ST) 2. INSPECT STARTER RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. Page 991 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 1768 Fuel Pressure: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See step 4). f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay, fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. 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 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 4429 4. DISCONNECT REAR SHOCK ABSORBER Remove the bolt and disconnect the shock absorber from the spring seat. Torque: 2WD (except pre runner): 26 Nm (260 kgf-cm, 19 ft. lbs.) 4WD and pre runner: 71 Nm (730 kgf-cm, 53 ft. lbs.) 5. REMOVE U-BOLTS a. Remove the 4 U-bolt mounting nuts and washers. b. Remove the spring seat and U-bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) HINT: At the time of installation, tighten the U-bolts so that the length of all the U-bolts under the spring seat is the same. c. 4WD and pre runner: Remove the spring bumper. 6. REMOVE LEAF SPRING a. Remove the nut, washer and hanger pin bolt. Torque: 157 Nm (1,600 kgf-cm, 116 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut b. Remove the 2 shackle pin mounting nuts and washers. Torque: 92 Nm (930 kgf-cm, 67 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. c. Remove the shackle pin plate, and rear leaf spring. REPLACEMENT Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Front Wheel Fastener: Service and Repair Front REPLACEMENT HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC 3. REMOVE HUB BOLT Using SST, 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 hammer handle or an equivalent to hold, install the bolt by torquing the nut. 5. INSTALL BRAKE DISC AND CALIPER 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 7. DEPRESS BRAKE PEDAL SEVERAL TIMES Page 4371 Locations Ignition Coil Locations ABS - Di Page 679 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT 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 3689 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Page 3016 Bu - VSV (Except Double Cab) Page 2061 Page 4541 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Page 1033 Engine Compartment Instrument Panel Locations Page 1291 Spark Plug: Specifications Torque Torque Spark Plug Torque 13 ft.lbf Page 32 Body Control System Specifications Fuel Pressure: Specifications Information not supplied by the manufacturer. Page 3948 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 2309 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 223 Step 6(Continued) - 8 Step 9 INSPECTION PROCEDURE Page 2288 CHART 1 Page 766 Power Window Switch: Testing and Inspection Driver's Switch Passenger's Switch (Window Unlock) Passenger's Switch : Window Lock 2 Door: INSPECT POWER WINDOW MASTER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Locations Ignition Switch: Locations Ignition Switch And Key Unlock Warning Switch Page 3832 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Specifications Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 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. * b. Do a visual check which includes the following items with the front passenger airbag assembly installed in the vehicle. Check for cuts, minute cracks or marked discoloration of the front passenger airbag door. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT 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 for cuts and cracks in, or marked discoloration of the front passenger airbag door. - Check for cuts and cracks in wire harnesses, and for chipping in connectors. - Check for deformation of the instrument panel and instrument panel reinforcement. HINT: If the instrument panel or instrument panel reinforcement is deformed, never repair it. Always replace it with a new one. Page 4664 Receiver Dryer: Service and Repair RECEIVER 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. DISCONNECT LIQUID TUBE BETWEEN RECEIVER AND COOLING UNIT Remove the bolt and disconnect the liquid tube. Torque: 6.0 N.m (60 kgf.cm, 52 in.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 the tube. 3. REMOVE LIQUID TUBE BETWEEN RECEIVER AND CONDENSER a. Loosen the nut and disconnect the liquid tube from condenser Torque: 14 N.m (140 kgf.cm, 10 ft.lbf) b. Remove the 2 bolts and disconnect the both tubes. Torque: 6.0 N.m (60 kgf.cm, 52 in.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 3 new O-rings with compressor oil and install the tube. 4. REMOVE RECEIVER FROM RECEIVER HOLDER Remove the holder bolt and pull the receiver upward from the holder HINT: At the time of installation, please refer to the following item. If receiver is replaced, add compressor oil to receiver Add 20 cc (0.71 fl.oz.) Compressor oil: ND-OIL 8 or equivalent INSTALLATION Installation is in the reverse order of removal. Page 1623 Oxygen Sensor: 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 2852 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. Locations Intake Air Temperature Sensor: Locations Engine Page 2827 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. Lower Ball Joint: Service and Repair Lower REMOVAL 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT TIE ROD END a. Loosen the 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) HINT: Do not remove the bolts. b. Remove the cotter pin and nut from the tie rod end. Torque: 90 Nm (930 kgf-cm, 67 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Page 3615 Fuse: Application and ID R/B No.2 Part-1 Page 114 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 4346 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 2208 Engine Control Module: Pinout Values and Diagnostic Parameters Terminals Of ECM/ Pinouts Part 1 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Page 910 Coolant: Fluid Type Specifications Coolant type: In order to avoid technical problems, only use "Toyota Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. Follow the manufacturers dilution recommendations on the label. 1. Do not use alcohol type antifreeze or plain water alone. 2. DO NOT FURTHER DILUTE PRE-MIXED MANUFACTURER APPROVED ETHYLENE GLYCOL BASED COOLANT IF USED. Locations Control Unit: Locations Instrument Panel Page 4436 Suspension Strut / Shock Absorber: Diagrams REAR SHOCK ABSORBER REPLACEMENT W/ RELATED COMPONENTS Page 4061 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 2028 A/F and 02 Sensor Identification Page 3121 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator. Maximum runout: 0.30 mm (0.0118 inch) If runout is not within the specification, try to correct by reorienting the installation of the torque converter clutch. HINT: Mark the position of the torque converter clutch to ensure correct installation. Page 3106 Drive/Propeller Shaft: Tools and Equipment SST (Special Service Tools) EQUIPMENT Page 684 1. REMOVE BATTERY a. Remove the bolt and battery clamp. b. Remove the battery and battery carrier. 2. REMOVE FRONT AIRBAG SENSOR RH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 nuts and front airbag sensor RH. 3. REMOVE FRONT AIRBAG SENSOR LH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 bolts and front airbag sensor LH. INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR LH AND RH Page 3588 Step 1 Page 646 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Page 960 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 squib connector. NOTE: Page 3264 A/C - Ho Page 1641 CHART 8 CHART 9 Page 2264 Knock Sensor Part 2 Page 3490 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. 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 3312 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 WITH 4 ANTI-SQUEAL SHIMS INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. Page 433 w/ Cruise Control If continuity is not as specified, replace the switch. Page 1628 Oxygen Sensor: 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 4069 "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 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. "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 3967 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 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 359 Engine Coolant Temperature (ECT) Sensor Page 2198 Engine Control Module (ECM) Page 1664 CHART 29 Diagrams Hydraulic Control Assembly - Antilock Brakes: Diagrams ABS ACTUATOR REPLACEMENT W/ RELATED COMPONENTS Locations Overdrive Switch: Locations Automatic Transmission Page 178 ^ 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 524 Page 2380 Engine Page 1452 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. Removal and Installation Brake Proportioning/Combination Valve: Service and Repair Removal and Installation LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) REMOVAL 1. DISCONNECT SHACKLE NO. 2 FROM BRACKET a. Remove the nut and disconnect the shackle No. 2. b. Remove the cushion retainer, 2 cushions and collar. Page 618 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 4093 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 2686 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Page 4490 Part 2 Of 2 DISASSEMBLY 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. Pre runner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 3. Pre runner: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER Page 66 Glossary Of Terms And Symbols Part 2 Page 547 CHART 18 CHART 19 Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Page 3651 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Page 3119 Flex Plate: Specifications Drive plate runout Maximum ............................................................................................................................................. .......................................... 0.20 mm (0.0079 inch) Torque converter clutch x Drive plate .................................................................................................................................. 41 Nm (420 kgf-cm, 30 ft. lbs.) Recall 03V146000: Fuel Hose Protector Installation Fuel Supply Line: All Technical Service Bulletins Recall 03V146000: Fuel Hose Protector Installation DEFECT: On certain double cab pickup trucks, during side impact NCAP testing, a flange at the rear end of the double cab body deformed and contacted the fuel inlet hose that connects the fuel filler pipe and fuel tank, resulting in damage to the fuel inlet hose. This damage could result in fuel leakage, which could result in a fire in the presence of an ignition source. REMEDY: Dealers will install a fuel hose protector on the body flange. The manufacturer has reported that owner notification is expected to begin during June 2003. Owners may contact Toyota at 1-800-331-4331. Page 2675 Engine Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Wiring Diagram Locations Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left Page 4141 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. Locations Switch: Locations A/C - Ho Locations Page 1088 Vehicle Lifting: Service and Repair Vehicle Lift And Support Locations Part 1 Testing and Inspection Heater Core: Testing and Inspection HEATER RADIATOR INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air. Locations Page 2404 b. Apply battery positive voltage across the terminals. c. Check that air flows from ports E to F If operation is not as specified, replace the VSV. 5. REINSTALL VSV a. Disconnect the connector and 2 vacuum hoses. b. Remove the bolt and VSV. 6. REMOVE VSV a. Disconnect the connector and 3 EVAP hoses from the VSV. b. Remove the bolt and VSV. Page 3906 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Circuit Opening Relay Fuel Pump Relay: Testing and Inspection Circuit Opening Relay INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and ohmmeter, check that there is continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 1428 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. Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Page 3836 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Page 2596 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 1830 Engine The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 4106 Page 3104 HINT: When replacing the propeller shaft, install new parts facing, as shown in the illustration. 1. 3-joint type: INSTALL CENTER SUPPORT BEARING ON INTERMEDIATE SHAFT Install the center support bearing and spacer. HINT: Install the center support bearing with the cutout toward the rear. 2. 3-joint type: INSTALL FLANGE ON INTERMEDIATE SHAFT a. Coat the splines of the intermediate shaft with MP grease. b. Place the flange on the shaft and align the matchmarks. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. Page 1718 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 2056 Locations Ignition Switch: Locations Ignition Switch And Key Unlock Warning Switch Page 811 CAUTION: - Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45014 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3 (See step 1). h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. 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 fuel hose connections, fuel pump, fuel filter and fuel pressure regulator k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kgf/sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. Locations Refrigerant Line Page 4150 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Page 1195 8. REINSTALL OIL PRESSURE SWITCH a. Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST, install the oil pressure switch. SST 09268-06021 Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 9. START ENGINE AND CHECK FOR LEAKS Page 3754 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 3550 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) lead from the switch body. Check that the clutch 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 reads the specified current. Specified current Page 2915 Step 3 - 4 Service and Repair Power Steering Bleeding: 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 and keep it there for 2 - 3 seconds, then turn the wheel to the opposite full lock and keep it there for 2 - 3 seconds. b. Repeat step (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 4356 Page 2737 Terminals Of ECM/Pinouts Part 1 Terminals Of ECM/Pinouts Part 2 Page 231 Engine Specifications Power Steering Fluid: Specifications Fluid ..................................................................................................................................................... ............................................ ATF DEXRON II or III Page 4022 BN7 - BV1 (Except Double Cab) BU1 Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Page 3740 Relay Box: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Testing and Inspection 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 After connection, adjust the control cable. Recall - Front Lower Ball Joint Replacement Technical Service Bulletin # SSC50J Date: 050501 Gap Spark Plug: Specifications Gap Gap Spark Plug Gap 1.1 mm (0.043 in.) Page 4089 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Page 1593 Engine Coolant Temperature (ECT) Sensor Page 84 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 1800 Spark Plug: Application and ID Recommended Spark Plug DENSO made ...................................................................................................................................... .............................................................. K16TR11 NGK made ........................................................................................................................................... ...................................................... BKR5EKB-11 Page 20 Cruise Control Module: Pinout Values and Diagnostic Parameters Terminals Of ECU/pinouts Page 538 CHART 5 CHART 6 Page 1770 r. Stop the engine. s. 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. t. 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 u. Remove the other union bolt 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks 3. INSPECT FUEL PUMP RESISTANCE a. Pull up the LH rear seat cushion. b. Remove the floor service hole cover with the 3 screws. c. Disconnect the fuel pump connector. d. Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 0.3 Ohm at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or set plate. 4. INSPECT FUEL PUMP OPERATION a. Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operations. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. Page 3485 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 435 Step 1 - 2 Page 4583 a. Disconnect the stator lead wire from the compressor housing. b. Using SST, remove the snap ring. SST 95994-10020 NOTE: At the time of reassembly, please refer to the following item. 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. Page 2115 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 2865 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 2750 El - Un Page 4768 b. Fix the steering wheel pad to the disc wheel with tire. 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. 2. 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 Page 3481 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 3799 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Specifications Camshaft Bearing: Specifications Camshaft bearing cap x Cylinder head ................................................................................................................................. 16 Nm (160 kgf-cm, 12 ft. lbs.) Page 2300 CHART 20 Page 555 CHART 24 Page 4205 Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.3 ± 2 mm, 0.05 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T .............................................................................................................. 0°07' ± 12' (0.11 - ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ................................................................................................................ 0°03' ± 12' (0.06° ± 0.2°, 0.7 ± 2 mm, 0.03 ± 0.08 inch) VZN170L-PRPDKAB Except off-road package Tire size: P225/75R15 102S ................................................................................................ 0°04' ± 12'(0.07° ± 0.2°, 0.8 ± 2 mm, 0.03 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ............................................................................................................... 0°04' ± 12' (0.07° ± 0.2°, 0.9 ± 2 mm, 0.04 ± 0.08 inch) Off-road package ................................................................................................................ 0°03' ± 12' (0.06° ± 0.2°, 0.8 ± 2 mm, 0.03 ± 0.08 inch) RZN171L-CRMDKAB Except off-road package Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.05 ± 0.08 inch) Tire size: P265/75R16 111S, P265/70R16 111T ............................................................................................................... 0°08' ± 12' (0.13° ± 0.2°, 1.6 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ............................................................................................................... 0°02' ± 12' (0.04° ± 0.2 °, 0.5 ± 2 mm, 0.02 ± 0.08 inch) RZN171L-CRPDKAB Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/75R16 111S, P265/70R16 111T ............................................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.5 ± 2 mm, 0.06 ± 0.08 inch) RZN191L-TRPDKAB Tire size: P225/75R15 102S ............................................................................................. 0° 07' ± 12' (0.12° ± 0.2 °, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111S .................................................................................................................. 0°08' ± 12' (0.8° ± 0.2', 1.6 ± 2 mm, 0.06 ± 0.08 inch) VZN195L-CRPDKAB Except off-road package Tire size: P225/75R115 102S ........................................................................................ 0 ° 06' ± 12' (0.10 ° ± 0.2 °, 1.1° ± 2 mm, 0.04 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111S ............................................................................................................... 0°06' ± 12' (0.10° ± 0.2°, 1.2 ± 2 mm, 0.05 ± 0.08 inch) Off-road package ................................................................................................................ 0°04' ± 12' (0.07° ± 0.2°, 0.8 ± 2 mm, 0.03 ± 0.08 inch) VZN195L-PRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................... 0°04' ± 12' (0.07° ± 0.2°, 0.9 ± 2 mm, 0.04 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ............................................................................................................... 0°04' ± 12' (0.07° ± 0.2°, 1.0 ± 2 mm, 0.04 ± 0.08 inch) Off-road package ..................................................................................................................... 0°03' ± 12' (0.06° ± 0.2 °, 0.8 ± 2 mm, 0.03 ± 0.08 inch) RZN196L-CRPDKAB Except off-road package Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ................................................................................................................. 0°08' ± 12' (0.8° ± 0.2°, 1.6 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ............................................................................................................... 0°04' ± 12' (0.07° ± 0.2 °, 0.8 ± 2 mm, 0.03 ± 0.08 inch) RZN196L-PRPDKAB Normal Tire size: P225/75R15 102S ................................................................................................ 0°04' ± 12' (0.07° ± 0.2', 1.0 ± 2 mm, 0.04 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ................................................................................................................. 0°05' ± 12' (0.08° ± 0.2°, 1.1. 2 mm, 0.04 ± 0.08 inch) Off-road package .................................................................................................................................. 0° 00' ± 12' (0° ± 0.2°, 0 ± 2 mm, 0 ± 0.08 inch) Wheel angle (max.) Inside wheel ......................................................................................................................................... ...................... 35°05' - 38°05' (35.08 - 38.08°) Outside wheel: Reference .......................................... .......................................................................................................................... 32°20' (32.33°) Page 3815 J/B No.3 - Behind The Instrument Panel Left Page 4674 Refrigerant Oil: Fluid Type Specifications Air Conditioning - Lubricant Air Conditioning - Lubricant ITEM CLASSIFICATION Compressor oil ND-OIL 8 or equivalent Page 1649 CHART 20 Page 1532 Terminals Of ECM/ Pinouts Part 2 Locations Fuel Pressure Regulator: Locations Fuel Pressure Regulator Part 1 Page 2604 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Page 3757 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Locations El - Un Locations Throttle Position Sensor: Locations Id - Wi Page 3580 Abbreviations Page 1969 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 Specifications Engine Oil Pressure: Specifications Oil pressure Normal operating temperature at idle speed ...................................................................................................................................................... 29 kPa (0.3 kgf/cm2, 4.3 psi) or more at 3,000 rpm ......................................................................................................................................... 245 - 520 kPa (2.5 - 5.3 kgf/cm2, 36 - 75 psi) Locations R/B No.2 - Engine Compartment Left Page 587 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Service and Repair Seals and Gaskets: Service and Repair REPLACEMENT HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. DRAIN DIFFERENTIAL OIL 2. DISCONNECT REAR PROPELLER SHAFT 3. REMOVE COMPANION FLANGE Page 3795 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 65 Glossary Of Terms And Symbols Part 1 Page 1636 O2S Application Table O2S Failure Threshold Charts Page 623 Engine Page 4770 c. 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 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. Page 4658 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 then 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 Removal and Installation Wheel Hub: Service and Repair Removal and Installation Part 1 Of 2 Page 1385 Thermostat: Diagrams THERMOSTAT REPLACEMENT W/ RELATED COMPONENTS Page 3966 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 3596 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 1921 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 1087 Vehicle Lift And Support Locations Part 2 Page 4156 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 3859 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Page 3956 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Cruise Control System (w/ETCS-i) Neutral Safety Switch: Testing and Inspection Cruise Control System (w/ETCS-i) Park/Neutral Position Switch Circuit (A/T) CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECM. When this signal is input during the cruise control driving, the ECM cancels the cruise control. Wiring Diagram Step 1 Page 74 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 2031 Page 4707 - Check the deformation on the horn button contact plate of the steering wheel pad. - Check the damage on the spiral cable connector and wire harness. 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. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACEMENT CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. AIRBAG HARNESS HINT: The SRS wire harness is integrated with the cowl wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube and all the connectors in the system are a standard yellow color. 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. * Page 4653 Heater Core Case: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE AIR MIX SERVOMOTOR 2. REMOVE AIR OUTLET SERVOMOTOR 3. REMOVE HEATER RADIATOR a. Remove the 5 screws and 2 plates and clamp. b. Pull out the heater radiator. c. Remove the 2 screws and 2 clips, then disconnect the heater radiator pipes. HINT: At the time of reassembly, please refer to the following item. Do not reuse 2 O-rings. 4. REMOVE AIR VENT DUCT Remove the 2 screws and duct. REASSEMBLY Reassembly is in the reverse order of disassembly. Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Page 3362 a. Adjust the length of the No. 2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure b. If the pressure cannot be adjusted by the No. 2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body c. Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Adjust the length of the No. 1 shackle again. If it cannot be adjusted, inspect the valve housing. 5. IF NECESSARY, CHECK VALVE BODY Page 1464 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 2841 ^ 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 3369 c. 4WD and Pre runner: Remove the 2 nuts, and remove the valve bracket and set plate from the valve body. 2. DISCONNECT SPRING FROM VALVE Using pliers, remove the clip, and remove the spring from the valve. 3. REMOVE SHACKLES NO.1 AND NO.2 a. Remove the nut and bolt, and remove the load sensing spring and 2 plate washers. b. Loosen the 2 nuts and washer, and remove the shackle No. 1 from the shackle No. 2. 4. DISASSEMBLE LOAD SENSING SPRING a. Remove the 4 bushings, 2 collars and 2 rubber plates. 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 Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Page 2904 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. NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. Page 3662 J/B No.3 - Behind The Instrument Panel Left Page 1056 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 3480 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 875 29. RECHECK ENGINE COOLANT LEVEL Page 119 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). Specifications Front Steering Knuckle: Specifications Steering knuckle x Brake caliper ..................................................................................................................................... 123 Nm (1,250 kgf-cm, 90 ft. lbs.) Steering knuckle x Dust cover .............................................................................................................................................. 18 Nm (185 kgf-cm, 13 ft. lbs.) Page 4521 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 3770 J/B No.3 Inner Circuit Page 2471 Injector Part 2 REMOVAL 1. REMOVE AIR CLEANER HOSE 2. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 3. REMOVE FUEL PRESSURE REGULATOR 4. DISCONNECT FUEL INLET PIPE Page 3899 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: 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 976 J/B No.1 - Lower Finish Panel Page 1564 Engine Capacity Specifications Fluid - Differential: Capacity Specifications Rear With Short Wheel Base With Rear differential Lock System .............................................................................................................................................. 2.65 Liters (2.8 US qt.) Without Rear differential Lock System .......................................................................................................................................... 2.55 Liters (2.7 US qt.) With Extra Long Wheel Base With Rear differential Lock System ............................................................................................................................................... 2.95 Liters (3.1 US qt.) Without Rear differential Lock System ........................................................................................................................................... 2.45 Liters (2.6 US qt.) Page 990 Fuse Block: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Page 3855 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. Page 2776 El - Un Page 1947 ^ 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. Locations Control Unit: Locations Instrument Panel Page 1003 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 1555 Circuit Opening Relay Recall 03V146000: Fuel Hose Protector Installation Fuel Supply Line: Recalls Recall 03V146000: Fuel Hose Protector Installation DEFECT: On certain double cab pickup trucks, during side impact NCAP testing, a flange at the rear end of the double cab body deformed and contacted the fuel inlet hose that connects the fuel filler pipe and fuel tank, resulting in damage to the fuel inlet hose. This damage could result in fuel leakage, which could result in a fire in the presence of an ignition source. REMEDY: Dealers will install a fuel hose protector on the body flange. The manufacturer has reported that owner notification is expected to begin during June 2003. Owners may contact Toyota at 1-800-331-4331. Page 1741 4. REINSTALL NO.2 TIMING BELT COVER Page 3658 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 4105 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. On-Vehicle Cleaning Radiator: Service and Repair On-Vehicle Cleaning ON-VEHICLE CLEANING INSPECT FINS FOR BLOCKAGE If fins are clogged, wash them with water or a steam cleaner and dry with compressed air. NOTICE: ^ It the distance between the steam cleaner and the core is too close, there is a possibility of damaging the fin, so keep the following injection distance. ^ If the fins are bent, straighten them with a screwdriver or pliers. ^ Never apply water directly onto the electronic components. Page 4364 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 3962 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 525 Engine Bank Identification Page 1489 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. Locations Knock Sensor: Locations Id - Wi Locations R/B No.2 - Engine Compartment Left Specifications Compression Check: Specifications Compression pressure at 250 rpm STD .......................................................................................................................................................... 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum .......................................................................... ..................................................................................... 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder ......................................................................................................... 100 kPa (1.0 kgf/cm2, 15 psi) or less Page 3461 Step 2 - 3 Upper Control Arm: Diagrams Upper FRONT UPPER SUSPENSION ARM REPLACEMENT W/ RELATED COMPONENTS Page 2853 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 2137 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 250 Engine Page 2445 Engine Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Engine Control Module -- Go to Powertrain Management Diagrams. Page 1104 3. 4WD: DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 5. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) c. Support the brake caliper securely. 6. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) Page 4096 Glossary Of Terms And Symbols Part 2 Page 3883 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 33 Daytime Running Lamp Relay: Testing and Inspection 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. Page 3947 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 3763 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 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 494 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 to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 3916 Diagram Legend Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. Connector Views: The connector views for connectors referred to within these diagrams can be found at the Vehicle level Connector Views. Page 3896 Step 1 Page 4179 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Locations Camshaft Position Sensor: Locations A/C - Ho Page 2073 El - Un Page 954 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, 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 Page 3605 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 3891 Auxiliary Power Outlet: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 3271 Hydraulic Control Assembly - Antilock Brakes: Service and Repair REMOVAL 1. DISCONNECT CONNECTOR 2. DISCONNECT BRAKE LINES Page 2982 El - Un Page 2308 CHART 25 Page 1855 Engine Page 4593 ABS - Di Steering/Suspension - Ball Joint Inspection Ball Joint: All 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 863 Timing Belt: Service and Repair Part 1 Of 2 Page 2533 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 1106 Wheel Hub: Service and Repair Disassembly and Assembly Part 1 Of 2 Locations Actuator: Locations Bu - VSV (Double Cab) Specifications Brake Master Cylinder: Specifications Master cylinder x Piston stopper bolt ................................................................................................................................. 8.0 Nm (80 kgf-cm, 69 inch lbs.) Master cylinder x Reservoir ............................................................................................................................................... 1.5 Nm (15 kgf-cm, 13 inch lbs.) Master cylinder x Brake booster ............................................................................................................................................. 13 Nm (130 kgf-cm, 9 ft. lbs.) Page 3597 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 527 Oxygen Sensor: 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 1970 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 535 O2S Application Table O2S Failure Threshold Charts Page 1662 Page 369 Cruise Control System (w/o ECTS-i) Page 2066 Page 221 Step 1 - 3 Page 4008 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Page 4679 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE a. Disconnect the pressure switch connector. b. Remove the pressure switch and O-ring. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mounted 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 the switch. INSTALLATION Installation is in the reverse order of removal. Page 871 c. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 5. INSTALL RH CAMSHAFT TIMING PULLEY a. Face the flange side of the timing pulley outward. b. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. c. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt to the crankshaft. b. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. c. Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover. SST 09960-10010 (09962-01000, 09963-01000) 7. INSTALL TIMING BELT NOTICE: The engine should be cold. a. Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Face the front mark on the timing belt forward. Page 3452 El - Un Locations Overdrive Switch: Locations Automatic Transmission Page 4395 Ball Joint: Service and Repair Upper Part 1 Of 2 Page 2451 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 1061 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Tools and Equipment 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 Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM 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. Page 4148 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Front Wheel Speed Sensor: Diagrams Front FRONT SPEED SENSOR REPLACEMENT W/ RELATED COMPONENTS Page 4094 Abbreviations Page 4178 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 1491 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 2251 Engine Page 3764 Relay Box: Connector Views J/B No.1 - Lower Finish Panel Page 156 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 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 966 J/B No.1 - Lower Finish Panel Page 2894 Terminals Of ECM/Pinouts Part 1 Terminals Of ECM/Pinouts 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 2097 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 4126 J/B No.1 Inner Circuit 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 2709 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. 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. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Page 154 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 4617 Specified amount: 650 ± 50 g (22.92 ± 1.76 oz.) 2. DISCONNECT LIQUID TUBE 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 1998 Idle Speed/Throttle Actuator - Electronic: Service and Repair Idle Air Control (IAC) Valve (w/o ETCS-i) IDLE AIR CONTROL (IAC) VALVE (w/o ETCS-i) REMOVAL 1. REMOVE THROTTLE BODY Page 4428 Suspension Spring ( Coil / Leaf ): Service and Repair REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 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 Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 3. 4WD: DISCONNECT PARKING BRAKE CABLE Page 2168 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. Locations Overdrive Switch: Locations Automatic Transmission Page 3514 c. Solder the brush wire to the brush holder at the specified exposed length. Exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) d. Check that the brush moves smoothly in the brush holder. e. Cut off the excess wire. f. Apply insulation paint to the soldered area. 2. REPLACE FRONT BEARING a. Remove the 4 screws, bearing retainer and bearing. b. Using a socket wrench and press, press out the bearing. c. Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00500) d. Install the bearing retainer with the 4 screws. Torque: 2.6 N.m (27 kgf.cm, 23 in.lbf) 3. REPLACE REAR BEARING Page 3248 El - Un Page 918 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. 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. Locations Electronic Brake Control Module: Locations Engine Compartment Page 4036 Engine Compartment Instrument Panel Locations Page 2579 Engine Specifications Steering Wheel: Specifications Steering wheel set nut ........................................................................................................................................................... 50 Nm (500 kgf-cm, 35 ft. lbs.) Steering wheel pad set screw (Torx screw) ........................................................................................................................ 9.0 Nm (90 kgf-cm, 78 inch lbs.) Locations Key Reminder Switch: Locations Ignition Switch And Key Unlock Warning Switch Page 1361 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 9 Electronic Brake Control Module: Testing and Inspection Terminals Of ECU / Pinouts Part 1 Page 4020 Multiple Junction Connector: Diagrams EA1 - EF1 IF1 - IL2 Page 3897 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 1719 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 1363 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. Page 193 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 920 Fluid - A/T: Service and Repair 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. NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. Page 4277 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 squib connector. NOTE: Testing and Inspection Interior Light Switch: Testing and Inspection INSPECT PERSONAL LIGHT SWITCH CONTINUITY a. Disconnect the connector from personal light switch. b. Turn the personal light switch ON, check that continuity exists between terminal 1 and body ground. If operation is not as specified, replace the switch. INSPECT ROOM LIGHT SWITCH CONTINUITY a. Disconnect the connector from room light switch. b. Turn the room light switch ON, check that continuity exists between terminal 2 and body ground. c. Turn the room light switch to DOOR, check that there is continuity between terminals 1 and 2. If operation is not as specified, replace the switch. Page 1487 ^ 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. Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant oil to be added when replacing components. Evaporater ........................................................................................................................................... .................................................... 40 cc (1.4 fl. oz.) Receiver/dryer ..................................................................................................................................... ................................................... 20 cc (.071 fl. oz) Condensor ........................................................................................................................................... .................................................... 40 cc (1.4 fl. oz.) Page 3532 Step 2 - 3 Page 152 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 3648 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 3968 Fuse Block: Connector Views J/B No.1 - Lower Finish 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. Interior - Dash Pad Rattles Air Register: Customer Interest Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Page 1016 J/B No.3 - Behind The Instrument Panel Left Page 2312 CHART 27 Page 2102 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 1987 Step 4 - 6 Page 1070 J/B No.1 - Lower Finish Panel Page 867 17. SET NO.1 CYLINDER AT TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt to the crankshaft. b. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. c. Check that the timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°). d. Remove the crankshaft pulley bolt. 18. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. 19. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. 20. REMOVE TIMING BELT 21. REMOVE RH CAMSHAFT TIMING PULLEY a. Using SST, loosen the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) b. Remove the bolt, knock pin and timing pulley. Page 258 Instrument Panel Page 257 Air Bag Control Module: Locations Airbag Sensor Assembly Page 4102 Step 1 Page 3566 Engine Page 2060 CHART 23 Page 1856 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Page 71 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 158 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. Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM 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. Locations R/B No.2 - Engine Compartment Left Page 2338 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Page 1586 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Page 1977 Engine Control Module: Locations Instrument Panel Page 3871 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Page 1630 ^ 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 2246 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 to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 2830 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 534 Page 1944 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 3666 J/B No.3 Inner Circuit Page 795 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 864 Part 2 Of 2 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT UPPER RADIATOR HOSE Page 3690 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Page 1107 Part 2 Of 2 DISASSEMBLY 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. Pre runner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 3. Pre runner: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER Interior - Dash Pad Rattles Air Register: All Technical Service Bulletins Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Page 4644 Heater Core: Service and Repair HEATER RADIATOR REMOVAL 1. REMOVE HEATER UNIT 2. REMOVE HEATER RADIATOR a. Remove the 5 screws and 2 plates and clamp. b. Pull out the heater radiator. c. Remove the 2 screws and 2 clips then disconnect the heater radiator pipes. HINT: At the time of reassembly please refer to the following item. Do not reuse 2 O-rings. INSTALLATION Installation is in the reverse order of removal. Locations Ignition Switch: Locations Ignition Switch And Key Unlock Warning Switch Page 1657 CHART 25 Page 1667 El - Un Page 2679 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Locations A/C - Ho Page 2777 Bu - VSV (Double Cab) Page 758 Bu - VSV (Double Cab) Page 1314 Water Pump: Service and Repair Part 1 Of 3 Page 4486 Part 2 Of 2 REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 4648 Heater Unit (Part 2) Page 796 Alignment: Specifications Front wheel Alignment ^ Vehicle height RZN161L-TRMDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -43 mm (-1.69 inch) Heavy duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -40 mm (-1.57 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -41 mm (-1.61 inch) RZN161L-TRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -43 mm (-1.69 inch) Heavy-duty leaf spring Tire size: P255/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ............................................................................................................... -40 mm (-1.57 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -41 mm (-1.61 inch) VZN170L-CRMDKAB Normal Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/75R15 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -44 mm (-1.73 inch) Tire size: P265/75R15 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -45 mm (-1.77 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 53 mm (2.10 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111S Rear: C*3 - D*4 .................................................................................................................................... ....................................... -39 mm (-1.54 inch) Tire size: P265/70R16 111T Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ............................................................................................................... -38 mm (-1.50 inch) VZN170L-CRPDKAB Normal Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -44 mm (-1.73 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -45 mm (-1.77 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 49 mm (1.93 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.64 inch) Heavy-duty leaf spring Tire size: P225/75R16 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -38 mm (-1.50 inch) Tire size: P265/70R16 111S Page 2662 4. REINSTALL NEW IGNITION COILS a. Connect a new ignition coil to the spark plug, and attach the ignition coil to the cylinder head cover. b. Install the ignition coil with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 5. RECONNECT HIGH-TENSION CORDS TO IGNITION COILS 6. REINSTALL AIR CLEANER HOSE Page 3728 Engine Compartment Instrument Panel Locations Page 3384 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: 8.0 Nm (80 kgf-cm, 69 inch 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 possibly that the cylinder bore could be damaged. ^ At the time of disassembly, 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 drops 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 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows. Page 1951 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 2340 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Engine Control Module -- Go to Powertrain Management Diagrams. Component Inspection Control Assembly: Testing and Inspection Component Inspection HEATER CONTROL ASSEMBLY INSPECTION 1. INSPECT ILLUMINATION OPERATION Connect the positive (+) lead from the battery to terminal 15 and negative (-) lead to terminal 16 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. 3. INSPECT RECIRC INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 7, 25. b. Push the REC button in and then check that the indicator lights up. If operation is not as specified, replace the switch circuit board. 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 3944 Fuse Block: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 533 Page 3808 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 Page 2801 ^ 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 2797 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 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 149 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 563 CHART 29 Page 4529 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 208 ^ 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 821 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. A/C switch is OFF. 2. CONNECT HAND-HELD TESTER OR OBD II SCAN TOOL a. Connect the hand-held tester or OBD II scan tool to the DLC3. b. Please refer to the hand-held tester or OBD II scan tool operator's manual for further details. 3. INSPECT IDLE SPEED a. Race the engine speed at 1,000 rpm for approximately 5 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT HAND-HELD TESTER OR OBD II SCAN TOOL Page 1500 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 2986 El - Un Page 1839 Camshaft Position Sensor Specifications Brake Shoe: Specifications Rear brake shoe lining thickness STD ..................................................................................................................................................... .............................................. 6.0 mm (0.236 inch) Minimum .............................................................. ............................................................................................................................. 1.0 mm (0.039 inch) Page 3063 Part 2 Of 2 REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE REAR WHEEL AND BRAKE DRUM Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. 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 (0.0039 inch) If the deviation exceeds the maximum, replace the axle shaft. 3. w/ ABS: REMOVE ABS SPEED SENSOR FROM REAR AXLE HOUSING Remove the bolt and ABS speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 4. REMOVE REAR BRAKE ASSEMBLY 2WD Page 2158 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 565 Oxygen Sensor: Locations A/C - Ho Page 3745 Step 1 Exploded Views Control Assembly: Exploded Views Heater Control Assembly (Part 1) Page 1480 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 2788 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 2103 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 1627 A/F and 02 Sensor Identification 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. Interior - Dash Pad Rattles Wiring Harness: All Technical Service Bulletins Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Page 4540 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 861 Timing Belt: Diagrams Part 1 Of 2 Page 3331 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 1426 ^ 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 1644 CHART 12 CHART 13 Page 1326 Coolant: Service and Repair REPLACEMENT 1. 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. Loosen the drain plugs, and drain the engine coolant. c. Close the drain plugs. 2. REFILL WITH ENGINE COOLANT a. Slowly fill the system with engine coolant. 1. Use of improper coolants may damage engine cooling system. 2. Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the manufacturer's directions. 3. 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%. DO NOT FURTHER DILUTE PRE-MIXED MANUFACTURER APPROVED ETHYLENE GLYCOL BASED COOLANT IF USED. NOTICE: Do not use an alcohol type engine coolant. - The engine coolant should be mixed with demineralized water or distilled water. Capacity b. Reinstall the radiator cap. c. Start the engine, and bleed the cooling system. d. If necessary, refill engine coolant into the reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Page 2261 Engine Page 4442 SST 09506-35010, 09632-36010 HINT: Do not apply grease or oil to the bushing. REASSEMBLY 1. INSTALL COIL SPRING TO SHOCK ABSORBER a. Using SST, compress the coil spring. SST 09727-30021 NOTICE: ^ To avoid damage to SST, set SST arms to allow clearance to hold a 8-roll coil between them. ^ 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. 2. INSTALL SUSPENSION SUPPORT a. Install the 2 cushions, 3 retainers and suspension support to the rod. b. Temporarily tighten a new suspension support center nut. c. Position the suspension support so that a line drawn between the 2 bolts would be parallel to the direction of the lower bushing. d. Remove the SST. SST 09727-30021 HINT: After removing the SST, again check the direction of the suspension support. e. Torque the suspension center nut. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) Page 4507 5. INSTALL AIR INLET SERVOMOTOR a. Install the servomotor with the 3 screws. b. Connect the servomotor connector. 6. INSTALL AIR DUCT 7. INSTALL GLOVE COMPARTMENT PARTS Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.) 2. DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. Page 3726 J/B No.1 - Lower Finish Panel Page 982 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 1595 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 to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 874 14. INSTALL FAN BRACKET a. Install the fan bracket with the bolt and nut b. Install the PS pump adjusting strut with the nut. 15. INSTALL NO.2 TIMING BELT COVER a. Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. 1. Using a screwdriver and gasket scraper, remove all the old gasket material. 2. Thoroughly clean all components to remove all the loose material. 3. Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. b. Install the timing belt cover with the 6 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c. Connect the 4 high-tension cord clamps and camshaft position sensor connector to the timing belt cover. 16. INSTALL OIL DIPSTICK AND GUIDE a. Install a new O-ring to the dipstick guide. b. Apply soapy water to the O-ring. c. Install the oil dipstick and guide to the cylinder block. d. Install the bolt to the generator bracket. Torque: 8 Nm (80 kgf-cm, 71 inch lbs.) 17. INSTALL A/C COMPRESSOR BRACKET Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.) 18. TEMPORARILY INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS 19. INSTALL NO.2 FAN SHROUD 20. INSTALL AND ADJUST DRIVE BELT FOR GENERATOR 21. TIGHTEN FAN WITH FLUID COUPLING AND FAN PULLEYS Torque: 5.4 Nm (54 kgf-cm, 48 inch lbs.) 22. CONNECT A/C COMPRESSOR TO ENGINE a. Install the A/C compressor with the 4 bolts. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) b. Install the drive belt. c. Connect the A/C compressor connector. 23. CONNECT PS PUMP TO ENGINE a. Temporarily install the PS pump with the bolt and nut. b. Install the drive belt. c. Tighten the bolt and nut. Torque: 43 Nm (440 kgf-cm, 31 ft. lbs.) d. Install the PS pressure tube clamp with the bolt. e. Connect the 2 PS air hoses to the air intake chamber and resonator. 24. CONNECT UPPER RADIATOR HOSE 25. FILL ENGINE WITH COOLANT 26. START ENGINE CHECK FOR LEAKS 27. INSTALL ENGINE UNDER COVER 28. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. Page 769 INSPECT REAR POWER WINDOW CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 544 CHART 14 Page 1460 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 1007 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 426 Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3623 J/B No.1 - Lower Finish Panel Details Page 2319 Engine Locations Idle Air Control (IAC) Valve (w/o ETCS-i) 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 715 Step 4 INSPECTION PROCEDURE Page 2228 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 122 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. On-Vehicle Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection On-Vehicle Inspection THERMISTOR ON-VEHICLE INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector from the thermistor. b. Using an ohmmeter, check that there is continuity between the terminals. Standard resistance: 1,500 ohms at 25 °C (77 °F) If resistance has no continuity, proceed next inspection. Page 4112 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Page 2670 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT 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 Page 26 Blower Motor Relay: Testing and Inspection HEATER MAIN RELAY INSPECTION INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Specifications Steering Wheel Pad And Spiral Cable Locations Id - Wi Page 1923 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 2029 Oxygen Sensor: 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 1958 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 1892 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 870 NOTICE: Never hold the tensioner push rod facing downward. c. Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 inch) If the protrusion is not as specified, replace the tensioner. INSTALLATION 1. INSTALL CRANKSHAFT TIMING PULLEY a. Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. b. Slide on the timing pulley, facing the flange side inward. 2. INSTALL NO.1 IDLER PULLEY a. Using a 10 mm hexagon wrench, install the plate washer and idler pulley with bolt. Torque: 35 Nm (350 kgf-cm, 26 ft. lbs.) b. Check that the pulley bracket moves smoothly. 3. INSTALL NO.2 IDLER PULLEY a. Install the idler pulley with the bolt. Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.) b. Check that the idler pulley moves smoothly. 4. INSTALL LH CAMSHAFT TIMING PULLEY a. Face the flange side of the timing pulley outward. b. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. Page 2402 b. Apply battery positive voltage across the terminals. c. Check that air does not flow from ports A to B. If operation is not as specified, replace the VSV 5. REINSTALL VSV Specifications Timing Belt: Specifications No.1 timing belt cover x Oil pump ....................................................................................................................................... 9 Nm (90 kgf-cm, 80 inch lbs.) Page 4006 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. 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 4251 1. MEASURE PS VANE PUMP ROTATING TORQUE a. Check that the pump rotates smoothly without abnormal noise. b. Using a torque wrench, check the pump rotating torque. Rotating torque: 0.27 Nm (2.8 kgf-cm, 2.4 inch lbs.) or less 2. REMOVE VANE PUMP PULLEY Using SST to stop the pulley rotating, remove the pulley set nut. SST 09960-10010 (09962-01000, 09963-01000) 3. REMOVE OIL RESERVOIR a. Remove the 3 bolts and oil reservoir. b. Remove the O-ring from the oil reservoir. 4. 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 union. 5. REMOVE BRACKET Remove the 2 bolts and bracket. 6. REMOVE REAR HOUSING a. Remove the 2 bolts. b. Remove the 2 O-rings from the rear housing. 7. REMOVE WAVE WASHER 8. REMOVE SIDE PLATE 9. REMOVE GASKET 10. REMOVE CAM RING, VANE PLATES AND VANE PUMP ROTOR a. Remove the cam ring and 10 plates. NOTICE: Take care not to drop the plate. b. Using a screwdriver, remove the snap ring from the vane pump shaft. c. Remove the vane pump rotor. 11. REMOVE VANE PUMP SHAFT 12. REMOVE STRAIGHT PINS Remove the 2 pins from the front housing. INSPECTION NOTICE: When using a vise, do not overtighten it. Page 2545 Idle Speed/Throttle Actuator - Electronic: Service and Repair Idle Air Control (IAC) Valve (w/o ETCS-i) IDLE AIR CONTROL (IAC) VALVE (w/o ETCS-i) REMOVAL 1. REMOVE THROTTLE BODY Page 1468 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 3863 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Page 3998 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Page 72 Step 1 Page 2825 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 1187 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2RZ-FE and 3RZ-FE: 5VZ-FE: 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY L3CK NUT TEMPORALLY Torque: 2.5 N.m (25 kgf.cm, 22 in..lbf) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 + 25 lbf Used belt: 100 + 25 lbf 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Page 1065 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 537 CHART 2 CHART 3 CHART 4 Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Wiring Diagram Page 1522 ^ 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 3657 "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 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. "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. Locations Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left 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, side airbag assembly, airbag sensor assembly, front airbag sensor side airbag sensor assembly or door side 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 4735 Instrument Panel Page 3202 Step 3 - 4 Page 3685 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Page 4165 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. Page 2698 Engine Page 3704 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Page 1461 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 1941 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 3803 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 4510 Air Door Actuator / Motor: Testing and Inspection Air Outlet Servomotor AIR OUTLET SERVOMOTOR INSPECTION 1. REMOVE LOWER LH FINISH PANEL 2. REMOVE AIR OUTLET SERVOMOTOR a. Disconnect the servomotor connector. b. Remove the 3 screws and servomotor. 3. INSPECT AIR OUTLET SERVOMOTOR Inspect servomotor operation. 1. Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1. 2. Check the lever operation when the negative (-) lead is connected to the terminals shown. HINT: The lever moves smoothly to the position for each mode. Page 972 J/B No.1 Part-3 Interior Panel Fuse Details Page 3784 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1057 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 2953 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 4493 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. Pre runner: INSTALL GREASE CAP Page 1311 Water Pump: Diagrams Part 1 Of 3 Page 137 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. 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 2641 Camshaft Position Sensor Page 580 Engine Testing and Inspection Control Module: Testing and Inspection Terminals Of ECM/Pinouts Page 558 CHART 26 Locations Camshaft Position Sensor: Locations A/C - Ho Removal and Installation Drive/Propeller Shaft: Service and Repair Removal and Installation REMOVAL Page 2099 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 1211 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 1634 Page 4191 When the cross camber or caster of the front wheel alignment is large it can cause vehicle pulling. If the cross camber or caster is within the specified range (30' or less), noticeable vehicle pulling will not occur due to side-to-side differences in camber or caster. NOTE On a flat road, if the cross camber or caster is 30' or less and the steering wheel is held without exerting steering effort for 109 yards (100 m) when driving at 62 mph (100 km/h), the alignment-induced drift distance is approximately 1.64 feet (0.5 m). 2. Relationship Between Tire Characteristics and Vehicle Pulling to One Side When radial tires are rotating they have the characteristic of generating force in the lateral direction between the tire and the road surface. This lateral force is comprised of two factors: ^ Ply-steer which changes direction according to the rotation direction of the tires. ^ Conicity which is generated in a fixed direction regardless of the tire rotation direction. If these lateral forces are too strong vehicle pulling will occur. A. Ply-Steer Lateral force due to ply-steer is produced by the construction of the belts inside the tire tread. With radial tires the wire of the belt is slanted as shown in the illustration below. Thus it is in the lateral direction that tire tread easily changes shape (stretches) and lateral force is generated between the tire and the road surface in the lateral direction. Lateral force from ply-steer prevents vehicle drift caused by road slant, so in many cases lateral force to the left is provided to compensate for road slant to the right. B. Conicity Conicity is lateral force resulting from uneven formation of the left and right sides of the tire. The direction the lateral force is exerted depends on the hardness of the side walls and the difference in height between the left/right sides of the tire. NOTE ^ In the case of vehicle pulling caused by tires, the lateral force which is exerted as a result of conicity has the greatest effect. On a flat road, Collision / Non-Collision Inspections Air Bag Harness: Testing and Inspection Collision / Non-Collision Inspections HINT: The SRS wire harness is integrated with the cowl wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube and all the connectors in the system are a standard yellow color. 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLE INVOLVED IN COLLISION a. Do a diagnostic system check. * b. Check for breaks in all wires of the SRS wire harness, and for 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 Trouble Codes. See: Testing and Inspection/Initial Inspection and Diagnostic Overview Page 92 J/B No.1 - Lower Finish Panel Page 3886 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 3837 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Specifications Valve Clearance: Specifications Valve clearance at cold Intake ................................................................................................................................................... ................ 0.13 - 0.23 mm (0.006 - 0.009 inch) Exhaust ..................................................................... ........................................................................................... 0.27 - 0.37 mm (0.011 - 0.014 inch) Page 1020 J/B No.3 Inner Circuit Page 2862 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 2832 ^ 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 4062 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Locations Transmission Temperature Sensor/Switch: Locations A/C - Ho Page 1467 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. Locations Timing Component Alignment Marks: Locations CAUTION: Incorrect removal or installation of the timing belt can result in damage to internal engine components. For complete Timing Belt Removal and Installation information, please refer to Timing Belt; Service and Repair. See: Timing Belt/Service and Repair INSTALL TIMING BELT NOTICE: The engine should be cold. a. Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Face the front mark on the timing belt forward. c. Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d. Install the timing belt to the No.2 idler pulley. e. Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f. Install the timing belt to the water pump pulley. g. Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h. Install the timing belt to the No.1 idler pulley. Page 3100 HINT: ^ Propeller shaft (pre runner) and rear propeller shaft (4WD) of joint type: Center bearing center line and the center bearing housing center line must be adjusted within 0 ± 1 mm (0 ± 0.04 inch) of each other in the vehicles front and rear direction when the vehicle is unloaded. ^ Propeller shaft (pre runner) and rear propeller shaft (4WD) of 3-joint type: When adjusting the center bearing housing center line, it should be perpendicular to the axis of front propeller shaft. ^ With a grease gun, pump grease into each fitting until it begins to flow around the oil seal. Grease: Spiders: Lithium base chassis grease, NLGI No.2. Sleeve yoke and double cardan joint: Molybdenum disulfide lithium base chassis grease, NLGI No. 2. Page 4090 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 4118 "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 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. "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 2142 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. Locations Starter Relay: Locations R/B No.2 - Engine Compartment Left Locations Vehicle Speed Sensor: Locations Id - Wi Page 1025 J/B No.1 - Lower Finish Panel Page 4177 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Page 1736 Engine Page 360 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19mm deep socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Locations ABS - Di Page 3007 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 4607 2. REMOVE CENTER CLUSTER FINISH PANEL 3. REMOVE HEATER CONTROL ASSEMBLY Remove the 3 screws and pull out the heater control assembly, then disconnect the 2 connectors. INSTALLATION Installation is in the reverse order of removal. Page 3752 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 4790 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 then 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. Locations ABS - Di Page 3861 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 1689 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Page 91 Relay Box: Connector Views J/B No.1 - Lower Finish Panel Page 1325 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the "LOW" and "FULL" lines. When the engine is cold. If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the "FULL" line. DO NOT FURTHER DILUTE PRE-MIXED MANUFACTURER APPROVED ETHYLENE GLYCOL BASED COOLANT IF USED. MIX ACCORDING TO THE MANUFACTURER'S DIRECTIONS. 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 water outlet filler hole, and the coolant should be free from oil. If they are excessively dirty, clean the coolant passages and replace the coolant. c. Reinstall the radiator cap. Page 2244 Engine Coolant Temperature (ECT) Sensor Page 3066 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) 7. INSTALL NEW OUTER OIL SEAL Using SST and a hammer, install a new oil seal. SST 09950-60010 (09951-00610), 09950-70010 (09951-07150) 8. REPLACE BEARING CASE a. Remove the oil seal (outer side) and bearing. b. Install 4 nuts to the serration bolts. c. Using a hammer, remove the serration bolts and bearing case. d. Position the backing plate on a new bearing case and using 2 socket wrenches, install the serration bolts. e. Install a new bearing and oil seal (outer side). 9. REPLACE OIL DEFLECTOR Page 551 CHART 22 Page 3972 Fuse Block: Electrical Diagrams J/B No.1 Inner Circuit Page 3809 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 3601 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 4314 b. Install the rack boot, dip and a new damp. NOTICE: Be careful not to damage or twist the boot. c. Tighten a new clamp with the screw, as shown in the illustration. 15. INSTALL RH AND LH 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.) 16. INSTALL 2 TURN PRESSURE TUBES a. Install 2 new union seats to the rack housing. b. Install 2 new union seats to the control valve housing. c. Using SST, install the 2 turn pressure tubes. SST 09023-38200 Torque: 23 Nm (235 kgf-cm, 17 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. Page 2278 A/F and 02 Sensor Identification Locations Page 3507 1. REMOVE GENERATOR DRIVE BELT a. Loosen the adjusting lock nut and pivot bolt. b. Loosen the adjusting bolt, and remove the drive belt. 2. REMOVE GENERATOR a. Disconnect the generator connector. b. Remove the nut, and disconnect the generator wire. c. Remove the pivot bolt and adjusting lock nut. d. Remove the generator. Torque: 51 N.m (520 kgf.cm, 38 ft.lbf) for pivot bolt 18.5 N.m (189 kgf.cm, 25 ft.lbf) for adjusting lock nut INSTALLATION Installation is in the reverse order of removal. Page 1566 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 2923 Step 5 INSPECTION PROCEDURE Page 1992 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. Locations Seat Belt Buckle Switch: Locations Bu - VSV (Double Cab) Specifications Water Pump: Specifications Water pump x Cylinder block .............................................................................................................................................. 20 Nm (200 kgf-cm, 14 ft. lbs.) Water inlet x Water pump .................................................................................................................................................... 20 Nm (200 kgf-cm, 14 ft. lbs.) Page 4265 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.). Locations Camshaft Position Sensor: Locations A/C - Ho Page 2054 CHART 18 CHART 19 Page 799 Tire size: P265/70R16 111T .............................................................................................................................................. 1°37' ± 45' (1.61° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................... 1°41'± 45' (1.69° ± 0.75°) Tire size: P265/70R16 111S .............................................................................................................................................. 1°43' ± 45' (1.71° ± 0.75°) Tire size: P265/70R16 111T .............................................................................................................................................. 1°41' ± 45' (1.68° ± 0.75°) RZN161L-TRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°37' ± 45' (1.62° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°38' ± 45' (1.64° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°37' ± 45' (1.61° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°42' ± 45' (1.70° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°43' ± 45' (1.71° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°41' ± 45' (1.69° ± 0.75°) VZN170L-CRMDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°42' ± 45' (1.70° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°43' ± 45' (1.72° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°41' ± 45' (1.69° ± 0.75°) Off-road package ................................................................................................... ............................................................. 2°02' ± 45' (2.03° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°50' ± 45' (1.83° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°51' ± 45' (1.85° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°49' ± 45' (1.82° ± 0.75°) VZN170L-PRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................... 2°36'± 45'(2.60° ± 0.75°) Tire size: P265/70R16 111S .............................................................................................................................................. 2°36'± 45' (2.61° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 2°35' ± 45' (2.59° ± 0.75°) Off-road package .............................................................................................................................................................. 2°39' ± 45' (2.66 ° ± 0.75°) VZN171L-CRMDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°44' ± 45' (1.74° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°45' ± 45' (1.75° ± 0.75°) Tire size: P265/70R16 111T ........................................................................................................................................... 1°44' ± 45' (1.73 ° ± 0.75 °) Off-road package ...................................................................................................... ......................................................... 2°02' ± 45' (2.03° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R16 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°52' ± 45' (1.87° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................ 1 °51' ± 45' (1.85° ± 0.75°) RZN171L-CRPDKAB Normal Tire size: P225/75R15 102S, P265/70R16 111S .............................................................................................................................................................. 1°44'± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°45' ± 45' (1.75° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R16 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°52' ± 45' (1.87° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°51' ± 45' (1.85° ± 0.75°) RZN191L-TRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°37' ± 45' (1.62° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°38' ± 45' (1.63° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°37' ± 45' (1.61° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°43' ± 45' (1.72° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°44' ± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................ 1°43' ± 45' (1.71° ± 0.75°) VZN195L-CRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................ 1°43' ± 45' (1.71° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°44' ± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T .............................................................................................................................................. 1°42'± 45' (1.70° ± 0.75°) Off-road package ................................................................................................... ............................................................ 1°56' ± 45' (1.93° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) Page 3904 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 3907 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Page 4743 - When installing the airbag sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL REMOVED PARTS Page 150 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 3992 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. Page 984 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 4764 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 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-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 3346 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 WITH 4 ANTI-SQUEAL SHIMS INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. Page 1651 CHART 21 Page 1972 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. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Page 545 CHART 15 Page 3671 J/B No.1 - Lower Finish Panel Page 1527 El - Un Page 3812 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 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 682 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction shown 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 and bottom sides, it will obstruct disconnection CONNECTION a. Align the male connector (of 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 the click can be heard at the time of fitting in.). HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. Page 3816 J/B No.3 - Behind The Instrument Panel Center Page 1652 CHART 22 Page 3392 Parking Brake Lever: Testing and Inspection ON-VEHICLE INSPECTION HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 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, 44.1 lbs.): 12 - 18 clicks 2. 2WD (except pre runner): IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. a. Loosen the lock nut. b. Tighten the adjusting nut until the travel is correct. Then tighten the lock nut. c. After adjusting the parking brake, confirm that the rear brakes are not dragging. 3. 4WD and pre runner: IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. a. Tighten 1 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. Page 3922 Engine Compartment Instrument Panel Locations Page 3912 "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 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. "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 3699 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. Locations Multiple Junction Connector: Locations EA1 - EF1, EA - EC IF1 - IL2, IE - IH Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Locations A/C - Ho Page 3533 Step 4 INSPECTION PROCEDURE Locations Id - Wi Page 4064 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Locations Transmission Control System Relay: Locations Instrument Panel Locations J/B No.1 - Lower Finish Panel Page 520 Engine Bank Identification Locations Three-way Catalytic Converter (TWC) System Page 1436 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 4431 d. Using SST and a press, install 2 new bushings. SST 09710-28012 (09710-07062), 09710-30041 (09710-03211) 3. REPLACE LEAF SPRING a. Bend to open the spring clip. Using a chisel and hammer, pry up the spring clip. b. Remove the center bolt. Hold the spring near the center bolt in a vise and remove the center bolt. 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. Page 3489 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 1697 Automatic Transmission Page 3025 El - Un Page 3031 Bu - VSV (Except Double Cab) Page 4453 Part 2 Of 2 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 626 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Page 4099 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Specifications Fuel Pressure: Specifications Information not supplied by the manufacturer. Page 1863 Data Link Connector: Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. Page 3627 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. 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 the wire routing is shown in square brackets [ ]. 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 Timing Component Alignment Marks: Locations CAUTION: Incorrect removal or installation of the timing belt can result in damage to internal engine components. For complete Timing Belt Removal and Installation information, please refer to Timing Belt; Service and Repair. See: Timing Belt/Service and Repair INSTALL TIMING BELT NOTICE: The engine should be cold. a. Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Face the front mark on the timing belt forward. c. Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d. Install the timing belt to the No.2 idler pulley. e. Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f. Install the timing belt to the water pump pulley. g. Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h. Install the timing belt to the No.1 idler pulley. Page 2532 Fuel Tank And Line Page 2287 O2S Application Table O2S Failure Threshold Charts Page 4144 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Page 4757 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. Locations Automatic Transmission Page 3061 Part 2 Of 2 REAR AXLE SHAFT REPLACEMENT W/ RELATED COMPONENTS Page 3749 Locations Combination Switch: Locations Body Control System Page 4640 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. Page 3643 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 4357 Diagrams Hydraulic Control Assembly - Antilock Brakes: Diagrams ABS ACTUATOR REPLACEMENT W/ RELATED COMPONENTS Page 132 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 4199 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 569 Air-Fuel Ratio (A/F) Sensor Heated Oxygen Sensor Page 2890 Shift Solenoid: Diagrams The shift solenoid identification and location in the valve body is contained in the valve body service and repair procedures and overhaul articles for most models. Page 557 Circuit Opening Relay Fuel Pump Relay: Testing and Inspection Circuit Opening Relay INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and ohmmeter, check that there is continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 2927 El - Un Page 3653 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 3949 Step 1 Page 1052 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 157 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 3705 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Page 2729 Step 1 - 2 Page 2151 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 3632 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 1539 Terminals Of ECM/ Pinouts Part 2 Page 2572 Engine Page 1267 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1. Check the A/F sensor or heated oxygen sensor operation. 2. See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 1812 SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size by following the Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T .......................................................................................................................................................... ........................ Thickness of used shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Page 4344 Page 4370 Page 1922 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 3232 El - Un Component Inspection Brake Light Switch: Testing and Inspection Component Inspection INSPECT STOP LIGHT SWITCH CONTINUITY w/o Cruise Control If continuity is not as specified, replace the switch. 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 3639 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 123 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 4123 J/B No.3 - Behind The Instrument Panel Left Page 2473 e. Place the 4 spacers in position on the intake manifold. f. Place the delivery pipes with the 6 injectors in position on the intake manifold. g. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold. h. 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. i. Position the injector connector outward. 2. CONNECT INJECTOR CONNECTORS 3. INSTALL FUEL PIPE AND TIGHTENING DELIVERY PIPE HOLDING BOLTS a. Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) b. Tighten the 4 bolts holding the delivery pipes to the intake manifold. Torque: 13 N.m (130 kgf.cm, 10 ft.lbf) 4. CONNECT FUEL INLET PIPE 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 233 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 1305 Intake: N = T - (A - 0.18 mm (0.007 inch)) Page 4073 J/B No.1 - Lower Finish Panel Page 3515 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 09820-00031 e. Using SST, push in the bearing cover (outside). SST 09285-76010 Page 288 El - Un Page 969 Fuse: Application and ID R/B No.2 Part-1 Lower Control Arm: Service and Repair Lower REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195-PRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE STEERING GEAR ASSEMBLY 3. DISCONNECT STABILIZER BAR LINK Remove the nut and disconnect the stabilizer bar link from the lower suspension arm. Torque: 90 Nm (920 kgf-cm, 66 ft. lbs.) Locations Wheel Speed Sensor: Locations A/C - Ho Page 1240 13. REMOVE FAN BRACKET a. Remove the nut and PS pump adjusting strut. b. Remove the bolt, nut and fan bracket. 14. REMOVE CRANKSHAFT PULLEY a. Using SST, loosen the pulley bolt SST 09213-54015 (90119-08216) 09330-00021 b. Remove the SST, pulley bolt and pulley. HINT: If necessary. remove the pulley with SST and a service bolt. SST 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05031) 15. REMOVE STARTER WIRE BRACKET AND NO.1 TIMING BELT COVER a. Remove the 2 bolts and starter wire bracket. b. Remove the 4 bolts and timing belt cover. 16. REMOVE TIMING BELT GUIDE Page 3455 Ignition 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. Recall 03V146000: Fuel Hose Protector Installation Fuel Return Line: All Technical Service Bulletins Recall 03V146000: Fuel Hose Protector Installation DEFECT: On certain double cab pickup trucks, during side impact NCAP testing, a flange at the rear end of the double cab body deformed and contacted the fuel inlet hose that connects the fuel filler pipe and fuel tank, resulting in damage to the fuel inlet hose. This damage could result in fuel leakage, which could result in a fire in the presence of an ignition source. REMEDY: Dealers will install a fuel hose protector on the body flange. The manufacturer has reported that owner notification is expected to begin during June 2003. Owners may contact Toyota at 1-800-331-4331. Page 498 Engine Page 3955 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Locations Canister Purge Solenoid: Locations Id - Wi Locations Switch: Locations A/C - Ho Page 3568 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Page 4390 Part 2 Of 2 FRONT UPPER BALL JOINT REPLACEMENT W/ RELATED COMPONENTS Page 1613 Knock Sensor Part 2 Page 493 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19mm deep socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 987 Abbreviations Page 4693 Evaporator Temperature Sensor / Switch: Testing and Inspection Component Inspection INSPECTION 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 3082 Wheel Hub: Service and Repair Disassembly and Assembly Part 1 Of 2 Page 3788 Glossary Of Terms And Symbols Part 2 Page 2826 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 4625 Evaporator Core: Service and Repair REMOVAL 1. REMOVE COOLING UNIT 2. REMOVE EVAPORATOR a. Using a knife, cut off each packing. b. Remove the 3 screws and 3 clips, then separate the upper and lower case. c. Disconnect the connector clamp. d. Remove the evaporator. HINT: At the time of installation, please refer to the following item. If evaporator is replaced, add compressor oil to evaporator. Add 40 cc (1.4 fl.oz.) Compressor oil: ND-OIL 8 or equivalent INSTALLATION Installation is in the reverse order of removal. Page 3438 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB REMOVE SPEED SENSOR a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. ^ The sensor is installed flat against the axle end when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 4708 2. VEHICLE INVOLVED IN COLLISION a. Do a diagnostic system check. * b. Check for breaks in all wires of the SRS wire harness, and for 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 Trouble Codes. REPLACEMENT In the following cases, replace the wire harness or connector. - If any part of the SRS wire harness or any connector has been found to be faulty in troubleshooting. - If any part of the SRS wire harness or any connector has been found to be faulty during checking items. NOTE: If the wire harness used in the SRS is damaged, replace the whole wire harness assembly. AIRBAG SENSOR ASSEMBLY 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION AND SRS IS NOT DEPLOYED Do a diagnostic system check. * 3. VEHICLES INVOLVED IN COLLISION AND SRS IS DEPLOYED Replace the airbag sensor assembly. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACEMENT 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: Be sure to follow the correct procedure, for removal and installation of the airbag sensor assembly. AIRBAG SENSOR FRONT Page 4374 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 1429 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 2050 CHART 12 CHART 13 Page 4449 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 2273 A/F and 02 Sensor Identification Page 1814 Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. Page 1089 Vehicle Lift And Support Locations Part 2 Locations ABS - Di Page 4103 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 4107 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 1438 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 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 1620 Specifications Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 Page 3833 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Page 4359 Page 1880 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 1730 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 10 Terminals Of ECU / Pinouts Part 2 Replacement Requirements Clockspring Assembly / Spiral Cable: Service and Repair Replacement Requirements REPLACEMENT CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. Locations Knock Sensor: Locations Id - Wi Page 4247 1. REMOVE AIR CLEANER ASSEMBLY Loosen the 3 bolts. 2. DISCONNECT RETURN HOSE NOTICE: Take care not to spill fluid on the drive belt. 3. DISCONNECT PRESSURE FEED TUBE a. Disconnect the connector from the oil pressure switch. b. Remove the oil pressure switch from the pressure feed tube. c. Remove the union bolt and 2 gaskets, and disconnect the tube from the PS vane pump assembly. 4. REMOVE DRIVE BELT a. Loosen the bolt A and nut B. b. Loosen the bolt C. 5. REMOVE PS VANE PUMP ASSEMBLY Remove the bolt A and nut B. INSTALLATION 1. INSTALL PS VANE PUMP ASSEMBLY Temporarily tighten the bolt A and nut B. 2. INSTALL DRIVE BELT a. Tightening the bolt C, adjust drive belt tension. b. Torque the bolt A and nut B. Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.) Page 4108 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 1432 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 3712 Multiple Junction Connector: Diagrams EA1 - EF1 IF1 - IL2 Page 2307 CHART 24 Testing and Inspection Idle Up Control Valve: Testing and Inspection AIR CONTROL VALVE INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine speeds decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine speeds increases when the hose is released. Page 1888 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 3915 Auxiliary Power Outlet: Electrical Diagrams Power Outlet Page 2238 4. REINSTALL NO.2 TIMING BELT COVER Electrical - SRS And HV Wiring Repairs Wiring Harness: All 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. Locations Shift Interlock Relay: Locations Instrument Panel Page 3582 Glossary Of Terms And Symbols Part 2 Page 3637 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms 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 3493 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-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. 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. Page 637 Camshaft Position Sensor Page 1670 Air-Fuel Ratio (A/F) Sensor Heated Oxygen Sensor Page 3129 Step 3 - 4 Page 2076 Air-Fuel Ratio (A/F) Sensor Heated Oxygen Sensor Page 3684 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. Page 334 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 676 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 1646 CHART 15 Locations Relay Box: Locations R/B No.2 - Engine Compartment Left Specifications Timing Belt: Specifications No.1 timing belt cover x Oil pump ....................................................................................................................................... 9 Nm (90 kgf-cm, 80 inch lbs.) Page 1387 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: 8.5 mm (0.335 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 1. INSTALL THERMOSTAT a. Place a new gasket to the thermostat. b. Install the thermostat with the jiggle valve downward. c. Install the water inlet with the 3 nuts. Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) 2. CONNECT LOWER RADIATOR HOSE 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR LEAKS Page 996 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Locations Automatic Transmission Page 1963 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 1769 CAUTION: - Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45014 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3 (See step 1). h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. 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 fuel hose connections, fuel pump, fuel filter and fuel pressure regulator k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kgf/sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. Locations A/C - Ho Page 4065 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 2064 Locations Shift Interlock Relay: Locations Instrument Panel Page 390 Evaporator Temperature Sensor / Switch: Testing and Inspection Component Inspection INSPECTION 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 4312 d. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00011 e. Loosen the cap until the rack guide spring is not functioning. f. Using SST and a torque wrench, tighten the cap until the preload is within specification. SST 09616-00011 Preload (turning): 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.) 12. INSTALL RACK GUIDE SPRING CAP LOCK NUT a. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Holding the rack guide spring cap rotating, and using SST, install the lock nut. SST 09922-10010 Torque: 51 Nm (521 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). c. Recheck the total preload. Preload (turning): 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.) d. Remove the RH and LH rack ends. 13. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS Page 2828 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 989 Glossary Of Terms And Symbols Part 2 Locations Acceleration/Deceleration Sensor: Locations ABS - Di Page 4023 Multiple Junction Connector: Application and ID EA1 - EF1 IF1 - IL2 BN7 - BR2 (Double Cab) BN7 - BV1 (Except Double Cab) BU1 Page 2235 Camshaft Position Sensor Locations Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left Page 4380 Page 1038 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 2048 CHART 10 Page 2843 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 2648 Engine Page 2040 Locations Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left Page 54 J/B No.1 - Lower Finish Panel Details Page 4596 Heater Control Assembly (Part 2) Page 4589 5. REMOVE CONDENSER a. Remove the liquid tube clamping bolt. b. Remove the 2 condenser mounting bolts and pull out the condenser. HINT: At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the condenser. 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. Page 999 Specifications Brake Pedal Assy: Specifications Brake pedal height (from asphalt seat) ................................................................................................................................ 154 - 168 mm (6.06 - 6.61 inch) Brake pedal freeplay ............................................................................................... .................................................................... 1 - 6 mm (0.04 - 0.24 inch) Brake pedal reserve distance at 490 N (50 kgf-cm, 110.2 lbs.) ............................................................................................. More than 105 mm (4.13 inch) Page 4761 Clockspring Assembly / Spiral Cable: Testing and Inspection Replacement Requirements REPLACEMENT CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering wheel pad. Locations Throttle Position Sensor: Locations Id - Wi Page 2211 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 210 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 1663 CHART 28 Page 3574 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. 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 the wire routing is shown in square brackets [ ]. 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 Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 Page 1235 Timing Belt: Diagrams Part 1 Of 2 Page 3807 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 731 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 1395 Part 2 Of 3 Page 3509 a. Remove the 4 screws and rectifier holder. b. 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. As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C). d. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. Page 800 Tire size: P265/70R16 111S ............................................................................................................................................. 1°53' ± 45' (1.88° ± 0.75°) Tire size: P265/70R16 111T .............................................................................................................................................. 1°51'± 45' (1.85° ± 0.75°) VZN195L-PRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 2°31' ± 45' (2.53° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 2°35' ± 45' (2.59° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 2°33' ± 45' (2.56° ± 0.75°) Off-road package ................................................................................................................................. .................................... 2°39' ± 45' (2.66° ± 0.75°) RZN196L-CRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°43' ± 45' (1.72° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°44' ± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°43' ± 45' (1.71° ± 0.75°) Off-road package ................................................................................................... ............................................................. 1°56' ± 45' (1.94° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................ 1 °52' ± 45' (1.87° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................ 1°51' ± 45' (1.85 ° ± 0.75°) RZN196L-PRPDKAB Normal Tire size: P225/75R15 102S .......................................................................................................................................... 2°34' ± 45' (2.58° ± 0.75°) Tire size: P265/70R16 111S .......................................................................................................................................... 2°35' ± 45' (2.59° ± 0.75°) Tire size: P265/70R16 111T .......................................................................................................................................... 2°33' ± 45' (2.56° ± 0.75°) Off-road package ........................................................................................................ ........................................................ 2°45'± 45' (2.75° ± 0.75°) Steering axis inclination Right - left error: 30' (0.5 or less) RZN161L models ............................................................................................................................................................. 10°30' ± 45' (10.5° ± 0.75°) VZN170L-CRMDKAB Except off-road package ................................................................................................................................................. 10°30' ± 45' (10.5° ± 0.75°) Off-road package ............................................................................................................................................................. 10°42' ± 45' (10.7° ± 0.75°) VZN170L-CRPDKAB Except off-road package ................................................................................................................................................. 10°30' ± 45' (10.5° ± 0.75°) Off-road package .......................................................................................................................................................... 10° 36' ± 45' (110.6° ± 0.75°) VZN170L-PRPDKAB ................................................................................................................................................... 11 °00' ± 45' (11.0° ± 0.75°) RZN171L-CRMDKAB Except off-road package ................................................................................................................................................. 10°24' ± 45' (10.4° ± 0.75°) Off-road package ............................................................................................................................................................. 10°49' ± 45' (10.7° ± 0.75°) RZN171L-CRPDKAB .................................................................................................................................................. 10°30' ± 45' (110.5° ± 0.75°) RZNI91L-TRPDKAB ..................................................................................................................................................... 10°24' ± 45' (10.4° ± 0.75°) VZN195L-CRPDKAB Except off-road package .................................................................................................................................................. 10°30'± 45' (10.5° ± 0.75°) Off-road package ............................................................................................................................................................. 10°36' ± 45' (10.6° ± 0.75°) VZN195L-PRPDKAB .................................................................................................................................................... 11°00' ± 45' (11.0° ± 0.75°) VZN196L-CRPDKAB Except off-road package ................................................................................................................................................. 10°24' ± 45' (10.4° ± 0.75°) Off-road package ............................................................................................................................................................. 10°36' ± 45' (10.6° ± 0.75°) VZN196L-PRPDKAB Normal ................................................................................................................................................. ........................... 10°54' ± 45' (10.9° ± 0.75°) Off-road package ................................................................................................................................. .................................. 11°12' ± 45' (11.2° ± 0.75°) ^ Toe - in (Total) .......................................................................................................................... Rack end length difference: 1.5 mm (0.059 inch) or less RZN161L-TRMDKAB Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.3 ± 2 mm, 0.05 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ............................................................................................................... 0°07' ± 12' (0.11° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) RZN161L-TRPDKAB Tire size: P225/75R125 102S ............................................................................................. 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ................................................................................................................. 0°07'± 12' (0.12° ± 0.2° 1.5 ± 2 mm, 0.06 ± 0.08 inch) VZN170L-CRMDKAB Except off-road package Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/75R16 111S, P265/70R16 111T ................................................................................................................ 0°07'± 12' (0.12° ± 0.2°, 1.5 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ................................................................................................................ 0°02' ± 12' (0.03° ± 0.2°, 0.4 ± 2 mm, 0.02 ± 0.08 inch) VZN170L-CRPDKAB Except off-road package Page 2167 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 1496 ^ 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 415 Body Control System Page 2518 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 2850 ^ 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 1879 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 2035 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 Locations El - Un Page 2544 3. INSPECT AIR ASSIST SYSTEM a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF b. Using SST connect terminals TC and CG of the DLC1. SST 09843-18040 c. After the engine speed is kept at 900 - 1300 rpm for 10 seconds, check that it returns to the idle speed. d. Stop the engine. e. Disconnect the air assist hose from the IAC valve, and plug it. f. Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors. g. Remove the SST from the DLC3. SST 09843-18040 h. Reconnect the air assist hose to the IAC valve. Page 1342 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 For installing the control cable, refer to "INSTALLATION" of HEATER CONTROL ASSEMBLY. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the clip and slide the clip along the hose. b. Disconnect the water hose. HINT: At the time of installation, please refer to the following item. Install the hose clip in the position, as shown in the illustration. Page 3950 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 2822 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: Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections 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: Bracket deformation - Paint peeling off the bracket - Cracks, dents or chips in the case - Cracks, dents, chipping and scratches in the connector - 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/Initial Inspection and Diagnostic Overview Page 3887 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 471 Engine Page 3943 Glossary Of Terms And Symbols Part 2 Page 1469 ^ 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 4296 2. REMOVE STEERING WHEEL PAD 3. REMOVE STEERING WHEEL 4. REMOVE ENGINE UNDER COVER Remove the 4 bolts and engine under cover. 5. DISCONNECT RH AND LH TIE ROD ENDS 6. DISCONNECT INTERMEDIATE NO. 2 SHAFT 7. DISCONNECT PRESSURE FEED AND RETURN TUBES Using SST, disconnect the pressure feed and return tubes. SST 09023-12700 8. REMOVE PS GEAR ASSEMBLY a. Remove the bolt and nut from the bracket. b. Remove the 2 set bolts and nut. c. Remove the 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. b. Install the gear assembly set bolt a . Torque: 167 Nm (1,700 kgf-cm, 123 ft. lbs.) c. Install the gear assembly set bolt "b" and nut "b". Torque: 191 Nm (1,950 kgf-cm, 141 ft. lbs.) d. Install the bolt "c" and nut "c" to the bracket. Torque: 167 Nm (1,700 kgf-cm, 123 ft. lbs.) 3. CONNECT PRESSURE FEED AND RETURN TUBES Using SST, connect the pressure tube and return tube. SST 09023-12700 Pressure feed tube: Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.) Return tube: Page 148 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 4084 J/B No.1 - Lower Finish Panel Details Page 3638 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Page 3484 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 3430 Bu - VSV (Double Cab) Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Page 3885 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 836 d. Reconnect and install the high-tension cords as shown in the illustration. Removal and Installation Blower Motor: Service and Repair Removal and Installation BLOWER UNIT Blower Unit REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH 2. REMOVE COWL SIDE TRIM RH Page 3624 Engine Compartment Instrument Panel Locations Page 3642 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 1494 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 1168 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). Page 4306 4. INSPECT BEARING a. Check the needle roller bearing of the rack hosing for marks or damage. If faulty, replace the rack housing. b. Coat the inside of the bearing with molybdenum) disulfide lithium base grease. 5. INSPECT BEARING a. Check the bearing rotation condition and check for abnormal noise. If the bearing is worn or damaged, replace the control Valve Assembly. b. Coat the bearing with molybdenum disulfide lithium base grease. 6. INSPECT BUSHING a. Check the inside of the bushing of the cylinder and stop per for cracks. If faulty, replace the bushing. b. Coat the inside of the bushing with molybdenum disulfide lithium base grease. 7. IF NECESSARY, REPLACE BUSHING a. Using a screwdriver, remove the bushing from the cylinder end stopper. NOTICE: Be careful not to damage the cylinder end stopper. b. Coat the inside of a new bushing with molybdenum disulfide lithium base grease. c. Install the bushing. 8. IF NECESSARY, REPLACE TEFLON RING AND 0RING Locations El - Un Page 3483 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 3910 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 Page 7 A/C - Ho Page 3041 El - Un Locations Air Bag Deactivation Switch: Locations El - Un Page 4588 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. REMOVE THESE PARTS: a. Radiator grille b. Horns c. Hood lock set bolts d. Center brace 3. REMOVE 2 LIQUID TUBES a. Remove the 2 bolts and disconnect the liquid tubes from receiver. Torque: 6.0 N.m (60 kgf.cm, 52 in.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 2 new O-rings with compressor oil and install the tubes. b. Loosen the 2 nuts and remove the 2 liquid tubes. Torque: 14 N.m (140 kgf.cm, 10 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 2 new O-rings with compressor oil and install the tubes. 4. DISCONNECT DISCHARGE HOSE FROM CONDENSER a. Remove the piping clamp set bolt. b. Remove the bolt and disconnect the hose. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Cap the open fitting 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-rings with compressor oil and install the tubes. Page 4075 J/B No.3 - Behind The Instrument Panel Center Page 232 Engine Page 510 Engine Page 240 Engine Page 4559 Blower Motor: Service and Repair Disassembly and Reassembly BLOWER UNIT DISASSEMBLY 1. REMOVE BLOWER MOTOR 2. REMOVE AIR INLET SERVO MOTOR REASSEMBLY Reassembly is in the reverse order of disassembly. Page 3086 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. Pre runner: INSTALL GREASE CAP Page 1656 CHART 24 Page 3431 Bu - VSV (Except Double Cab) Page 4639 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 For installing the control cable, refer to "INSTALLATION" of HEATER CONTROL ASSEMBLY. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the clip and slide the clip along the hose. b. Disconnect the water hose. HINT: At the time of installation, please refer to the following item. Install the hose clip in the position, as shown in the illustration. Page 58 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. 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 the wire routing is shown in square brackets [ ]. 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 3465 Step 4 INSPECTION PROCEDURE Page 1928 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 2148 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. 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 1027 Engine Compartment Instrument Panel Locations Testing and Inspection Idle Up Control Valve: Testing and Inspection AIR CONTROL VALVE INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine speeds decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine speeds increases when the hose is released. Specifications Idle Speed: Specifications Idle speed ............................................................................................................................................ ............................................................. 700 ± 50 rpm Page 2756 El - Un Page 1724 Engine Page 430 Automatic Transmission Diagrams Axle Shaft: Diagrams Part 1 Of 2 Specifications Front Steering Knuckle: Specifications Steering knuckle x Brake caliper ..................................................................................................................................... 123 Nm (1,250 kgf-cm, 90 ft. lbs.) Steering knuckle x Dust cover .............................................................................................................................................. 18 Nm (185 kgf-cm, 13 ft. lbs.) Page 2932 Terminals Of ECM/Pinouts Part 1 Terminals Of ECM/Pinouts Part 2 Page 2046 CHART 7 Front Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber Removal and Installation REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-RPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Specifications Fuel Pressure: Specifications Information not supplied by the manufacturer. Page 78 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 2133 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 2417 Bu - VSV (Except Double Cab) Page 4172 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Locations Camshaft Position Sensor: Locations A/C - Ho Specifications Suspension Strut / Shock Absorber: Specifications Shock absorber x Suspension support .................................................................................................................................. 29 Nm (300 kgf-cm, 22 ft. lbs.) Lower suspension arm x Shock absorber ..................................................................................................................... 135 Nm (1,400 kgf-cm, 101 ft. lbs.) Page 3600 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 3462 Step 4 INSPECTION PROCEDURE Page 2058 CHART 22 Locations Transmission Mode Switch: Locations Automatic Transmission Page 1008 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 3504 b. Check the negative (-) rectifier. 1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. 2. Reverse the polarity of the tester probes and repeat step (a). 3. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 6. INSPECT BEARING Check the bearing is not rough or worn. If necessary, replace the bearing. Page 1996 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) VALVE (w/o ETCS-i) ON-VEHICLE INSPECTION 1. INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF b. Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 c. After engine speed is kept at approx. 1,000 rpm for 5 seconds, check that it returns to the idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST from the DLC3. SST 09843-18040 2. INSPECT IAC VALVE RESISTANCE NOTE: "Cold" and "Hot" in the following 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). a. Disconnect the IAC valve connector. b. Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). If the resistance is not as specified, replace the IAC valve. c. Reconnect the IAC valve connector. Locations Transmission Temperature Sensor/Switch: Locations A/C - Ho Page 1518 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 790 When it is determined by troubleshooting that the vehicle pulling to one side is caused by wheel alignment perform repairs according to the following procedure. NOTE ^ Keep the cross camber within 10 or less. ^ Keep the camber of each wheel within specifications (+/-45' of center value). ^ If adjustment exceeds the specifications, uneven tire wear will result. 3. Vehicle Pulling Caused by Tire Conicity. When it is determined by troubleshooting that the vehicle pulling to one side is caused by tire conicity perform repairs according to the following procedures. Indication of Tire Conicity as a Cause: When the front tires are switched, the pulling direction changes. Proceed to step 3A below. A. Remove the front left tire from the wheel and reverse the tire. Then perform a road test and check for change in the pulling direction. Gap Spark Plug: Specifications Gap Gap Spark Plug Gap 1.1 mm (0.043 in.) Page 932 8. REINSTALL OIL PRESSURE SWITCH a. Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST, install the oil pressure switch. SST 09268-06021 Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 9. START ENGINE AND CHECK FOR LEAKS Page 2710 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Page 713 Neutral Safety Switch: Testing and Inspection Cruise Control System (w/o ETCS-i) Park/Neutral Position Switch Circuit (A/T) CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during the cruise control driving, the ECU cancels the cruise control. Wiring Diagram Step 1 Page 541 CHART 10 Page 2589 Engine Page 3686 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Locations Transmission Mode Switch: Locations Automatic Transmission Page 3766 J/B No.3 - Behind The Instrument Panel Left Page 4010 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Page 145 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 4278 - 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 4669 Refrigerant: Fluid Type Specifications Type R-134a Page 3946 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Page 2134 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 3739 Glossary Of Terms And Symbols Part 2 Page 4756 Steering Wheel Pad And Spiral Cable Page 3882 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. 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 the wire routing is shown in square brackets [ ]. 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 3958 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Vehicle Lift and Support Locations (Double Cab) Vehicle Lifting: Locations Vehicle Lift and Support Locations (Double Cab) Vehicle Lift and Support Locations Diagrams Wheel Hub: Diagrams Part 1 Of 2 Specifications Water Pump: Specifications Water pump x Cylinder block .............................................................................................................................................. 20 Nm (200 kgf-cm, 14 ft. lbs.) Water inlet x Water pump .................................................................................................................................................... 20 Nm (200 kgf-cm, 14 ft. lbs.) Page 4050 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Page 1478 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. 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 Page 4095 Glossary Of Terms And Symbols Part 1 Page 3959 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Page 3492 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) Capacity Specifications Refrigerant: Capacity Specifications Capacity 600 ± 50 g (21.16 ± 1.76 oz.) Locations Control Unit: Locations Instrument Panel Page 53 J/B No.1 - Lower Finish Panel Page 4508 Air Door Actuator / Motor: Testing and Inspection Air Mix Servomotor AIR MIX SERVOMOTOR INSPECTION 1. REMOVE AIR MIX SERVOMOTOR a. Disconnect the servomotor connector. b. Remove the 3 screws and servomotor. 2. INSPECT AIR MIX SERVOMOTOR a. Inspect servomotor operation. 1. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, then check that the arm turns to "COOL" side smoothly. 2. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, then check that the arm turns to "WARM" side smoothly. If operations are not as specified, replace the servomotor. b. Inspect position sensor resistance. Locations Electronic Brake Control Module: Locations Engine Compartment Locations Crankshaft Position Sensor: Locations A/C - Ho Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Wiring Diagram Page 792 ^ The method of camber adjustment differs for different models, so please refer to the Repair Manual of the vehicle involved. (The information below are samples from the Sienna Repair Manual.) A. Remove the front wheels and ABS speed sensor clamp. B. Remove the two nuts on the lower side of the shock absorber. C. Coat the threads of the nuts with engine oil. D. Temporarily install the two nuts. E. Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. F. Tighten the nuts. Torque: 210 N*m (2150 kgf*cm, 155 ft*lbf) G. Install the front wheels. Torque: 104 N*m (1050 kgf*cm, 77 ft*lbf) H. Check the camber. Page 3862 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Page 4736 ABS - Di Page 4034 J/B No.1 - Lower Finish Panel Page 1051 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 3981 Engine Compartment Instrument Panel Locations Page 2164 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). Air Inlet Servomotor Air Door Actuator / Motor: Testing and Inspection Air Inlet Servomotor AIR INLET SERVOMOTOR INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS 2. REMOVE AIR DUCT 3. REMOVE AIR INLET SERVOMOTOR a. Disconnect the servomotor connector. b. Remove the 3 screws and servomotor. 4. INSPECT AIR INLET SERVOMOTOR Inspect servomotor operation. 1. Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 3, then check that the arm turns to "FRS" side smoothly. 2. Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 1, then check that the arm turns to "REC" side smoothly. If operations are not as specified, replace the servomotor. Page 2484 Fuel Pressure Regulator Part 2 REMOVAL 1. REMOVE AIR CLEANER HOSE 2. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 3. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR CAUTION: Put a shop rag under the pressure regulator. 4. REMOVE FUEL PRESSURE REGULATOR a. Remove holding bolt the engine wire to the LH cylinder head cover. b. Disconnect the protector from the bracket on the RH cylinder head cover, and lift up the engine wire. Page 968 Engine Compartment Instrument Panel Locations Page 4164 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM 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. 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 Locations Switch: Locations A/C - Ho Locations Transmission Mode Switch: Locations Automatic Transmission Page 1794 d. Reconnect and install the high-tension cords as shown in the illustration. Page 2201 Engine Control Module: Connector Views Terminals Of ECM/ Pinouts Part 1 Page 4789 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction shown 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 and bottom sides, it will obstruct disconnection CONNECTION a. Align the male connector (of 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 the click can be heard at the time of fitting in.). HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. Page 3831 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. Page 2699 Engine Circuit Opening Relay Fuel Pump Relay: Testing and Inspection Circuit Opening Relay INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and ohmmeter, check that there is continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 817 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1. Check the A/F sensor or heated oxygen sensor operation. 2. See the table for possible causes, and then inspect and correct the applicable causes if necessary. 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 3105 c. Install the spacer. d. Using SST to hold the flange, press the bearing into position by tightening down a new nut. SST 09330-00021 Torque: 181 Nm (1,850 kgf-cm, 134 ft. lbs.) e. Loosen the nut. f. Torque the nut again. Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.) g. Using a chisel and hammer, stake the nut. 3. 3-joint type: CONNECT PROPELLER SHAFT AND INTERMEDIATE SHAFT a. Align the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. b. Torque the nuts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) 4. INSERT SLEEVE YOKE INTO PROPELLER SHAFT a. Apply grease to the propeller shaft spline and sleeve yoke sliding surface. Grease: Molybdenum disulfide lithium base chassis grease, NLGI No. 2. b. Install the dust cover to the shaft. c. Align the matchmarks on the yoke and propeller shaft. Page 2456 Fuel: Specifications Fuel Type Unleaded Gasoline Octane Rating 87 Octane or Higher Page 4580 2. INSTALL COMPRESSOR a. Install the compressor with 4 bolts. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) b. Connect the connector. 3. CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with the 2 bolts. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) NOTE: Hose should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O-rings with compressor oil and install the hoses. 4. INSTALL AND CHECK DRIVE BELT 5. INSTALL ENGINE UNDER COVER 6. 5VZ-FE Engine Models: INSTALL PS PUMP SET BOLT AND NUT Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 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. 11. INSPECT A/C OPERATION Locations Component Tests and General Diagnostics Air Bag Control Module: Component Tests and General Diagnostics Collision / Non-Collision Inspections 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION AND SRS IS NOT DEPLOYED Do a diagnostic system check. * 3. VEHICLES INVOLVED IN COLLISION AND SRS IS 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/Initial Inspection and Diagnostic Overview Replacement Requirements REPLACEMENT 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: Be sure to follow the correct procedure, for removal and installation of the airbag sensor assembly. Page 2188 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 4309 SST 09951-60010 (09951-00330, 09951-00490, 09952-06010), 09951-70010 (09951-07360) NOTICE: ^ Make sure to install the oil seal facing 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 09631-00350 HINT: If necessary, scrape the burrs off the rack teeth end and burnish. b. Coat SST with power steering fluid. c. Install the rack into the rack housing. d. Remove the SST. 4. INSTALL OIL SEAL a. Install SST to the steering rack opposite end. SST 09631-00350 b. Coat SST with power steering fluid. c. Coat a new oil seal lip with power steering fluid, and install it by pushing it onto the SST without tilting. NOTICE: Make sure to install the oil seal facing the correct direction. d. Remove the SST 5. INSTALL CYLINDER END STOPPER a. Coat a new O-ring with power steering fluid, and install it to the cylinder end stopper. Page 4600 Check the continuity between terminals while switch is pressed, as shown in the chart. 8. INSPECT TEMPERATURE CONTROL SWITCH OPERATION a. Check that the resistance between terminals 11 and 13 is approx. 3.0 K ohms b. Connect the positive (+) lead from the three 1.5 V dry cell batteries to terminal 11 and negative (-) lead to terminal 13. c. Connect the positive (+) lead from the tester to terminal 12 and negative (-) lead to terminal 13. d. Gradually turn the switch from "MAX. WARM" side to "MAX. COOL" side and check that the voltage increase from 0 to 4.5 V. If operation is not as specified, replace the heater control base. 9. INSPECT BLOWER SPEED CONTROL SWITCH OPERATION Check the continuity between terminals at each switch position as shown in the chart. If continuity is not as specified, replace the heater control base. Locations Intake Air Temperature Sensor: Locations Engine Page 4014 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Page 1427 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 4489 Wheel Hub: Service and Repair Disassembly and Assembly Part 1 Of 2 Page 3628 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Specifications Valve Clearance: Specifications Valve clearance at cold Intake ................................................................................................................................................... ................ 0.13 - 0.23 mm (0.006 - 0.009 inch) Exhaust ..................................................................... ........................................................................................... 0.27 - 0.37 mm (0.011 - 0.014 inch) Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Page 4045 Abbreviations Page 4256 Install a new gasket on the front housing. NOTICE: Be careful the direction of the gasket. 8. INSTALL SIDE PLATE Align the holes of the plate and 2 straight pins. 9. INSTALL WAVE WASHER Install the washer so that its protrusions fit into the slots in the side plate. 10. 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 2 bolts. Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.) 11. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION a. Install the spring. 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 union. Torque: 83 Nm (850 kgf-cm, 62 ft. lbs.) 12. INSTALL BRACKET Install the bracket with the 2 bolts. Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.) 13. INSTALL OIL RESERVOIR a. Coat a new O-ring with power steering fluid and install it to the oil reservoir. b. Install the oil reservoir with the 3 bolts. Torque: Front side bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) Rear side bolts: 24 Nm (240 kgf-cm, 17 ft. lbs.) 14. INSTALL VANE PUMP PULLEY Using SST to stop the pulley rotating, torque the nut. SST 09960-10010 (09962-01000, 09963-01000) Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.) 15. MEASURE PS VANE PUMP ROTATING TORQUE Page 1434 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 4300 Part 3 Of 3 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Page 2283 Page 2678 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 184 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 1824 Engine Locations Instrument Panel Locations Transmission Control System Relay: Locations Instrument Panel Page 674 A/C - Ho Page 4146 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Page 1929 ^ 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 2245 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19mm deep socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 3544 Starter Motor: Testing and Inspection INSPECTION 1. INSPECT ARMATURE COIL a. Check the 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. b. Check the 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. 2. INSPECT COMMUTATOR a. Check the commutator for the dirty and burnt surfaces. If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. b. Check for the commutator circle runout. 1. Place the commutator on V-blocks. 2. Using a dial gauge, measure 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. Page 2624 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Page 4602 Control Assembly: Testing and Inspection On-Vehicle Inspection HEATER CONTROL ASSEMBLY ON-VEHICLE INSPECTION 1. INSPECT HEATER CONTROL DIALS OPERATION Move the control dials left and right check for stiffness and binding the full range of the dials. 2. REMOVE HEATER CONTROL ASSEMBLY 3. INSPECT AMPLIFIER CIRCUIT a. Inspect the connector on wire harness side, as shown in the chart. Test conditions: Turn ignition switch to ON - Blower speed switch HI - Temperature control lever Max. COOL b. Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart. Test conditions: Turn ignition switch to ON Page 757 El - Un Page 1068 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 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 Crankshaft Main Bearing: Specifications Main bearing cap x Cylinder block 1st ................................................................................................. ........................................................................................ 61 Nm (625 kgf-cm, 45 ft. lbs.) 2nd ............ .............................................................................................................................................................. ........................ Turn 90Turn 90Turn 90° Page 570 Oxygen Sensor: Service Precautions MAINTENANCE PRECAUTIONS Precautions when the handling oxygen sensors. 1. Do not allow oxygen sensor to drop or hit against an object. 2. Do not allow the sensor to come into contact with water. Page 2556 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 2778 Bu - VSV (Except Double Cab) Locations ABS - Di Specifications Compression Check: Specifications Compression pressure at 250 rpm STD .......................................................................................................................................................... 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum .......................................................................... ..................................................................................... 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder ......................................................................................................... 100 kPa (1.0 kgf/cm2, 15 psi) or less Page 1801 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. 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. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Page 2293 CHART 10 Page 3549 b. Check the hold-in coil for open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. 10. INSPECT BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 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 clutch pinion gear moves outward. 2. DO HOLD-IN TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out. Page 1997 3. INSPECT AIR ASSIST SYSTEM a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF b. Using SST connect terminals TC and CG of the DLC1. SST 09843-18040 c. After the engine speed is kept at 900 - 1300 rpm for 10 seconds, check that it returns to the idle speed. d. Stop the engine. e. Disconnect the air assist hose from the IAC valve, and plug it. f. Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors. g. Remove the SST from the DLC3. SST 09843-18040 h. Reconnect the air assist hose to the IAC valve. Testing and Inspection Control Module: Testing and Inspection Terminals Of ECM/Pinouts Page 2449 Engine Page 93 J/B No.3 - Behind The Instrument Panel Left Page 276 Engine Page 1355 2. REMOVE RADIATOR SUPPORTS Using a torx wrench, remove the 4 torx screws and the 2 radiator supports. Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool) HINT: Lift up the floor carpet and loosen the screwed REASSEMBLY Reassembly is in the reverse order of disassembly. Page 174 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 1661 CHART 27 Locations Vehicle Speed Sensor: Locations Id - Wi Page 2503 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Locations R/B No.2 - Engine Compartment Left Page 883 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 658 Engine Locations Fuel Pump Relay: Locations ABS - Di Page 2071 CHART 30 Page 2978 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator. Maximum runout: 0.30 mm (0.0118 inch) If runout is not within the specification, try to correct by reorienting the installation of the torque converter clutch. HINT: Mark the position of the torque converter clutch to ensure correct installation. Page 410 INSPECT FUEL LEVEL WARNING SWITCH a. Apply battery positive voltage between terminals 1 and 3, and through a 3.4 W test bulb, and check that the bulbs 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 377 Cruise Control System (w/o ECTS-i) Page 1619 Applicable Vehicles Page 95 Relay Box: Electrical Diagrams J/B No.1 Inner Circuit Page 4765 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 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. Page 1459 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 2096 ^ 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 4298 Steering Gear: Service and Repair Disassembly and Assembly Part 1 of 3 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. Recall - Front Lower Ball Joint Replacement Technical Service Bulletin # SSC50J Date: 050501 Page 1624 Applicable Vehicles Exploded Views Blower Unit Page 2700 Knock Sensor Part 1 Page 2042 O2S Application Table O2S Failure Threshold Charts Page 1260 Fuel Pressure: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See step 4). f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay, fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. 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 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 1600 Engine Page 225 Terminals Of ECM/ Pinouts Part 2 Page 4491 a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using 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/ spacer. 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 1047 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Page 1531 Engine Control Module: Connector Views Terminals Of ECM/ Pinouts Part 1 Page 1565 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 1237 Timing Belt: Service and Repair Part 1 Of 2 Page 1360 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 139 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 4403 Control Arm: Diagrams Lower FRONT LOWER SUSPENSION ARM REPLACEMENT W/ RELATED COMPONENTS Page 1737 Engine Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 146 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. Gap Spark Plug: Specifications Gap Gap Spark Plug Gap 1.1 mm (0.043 in.) Page 1949 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 2848 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 2263 Knock Sensor Part 1 w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 203 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. 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 1989 Engine Control Module: Pinout Values and Diagnostic Parameters Terminals Of ECM/ Pinouts Part 1 Page 4206 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). INSPECTION HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. MEASURE VEHICLE HEIGHT Measuring points: A: Ground clearance of spindle center B: Ground clearance of front adjusting cam bolt center C: Ground clearance of rear axle shaft center D: Ground clearance of leaf spring front hanger pin bolt center 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-KINGPIN 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 Page 2055 CHART 20 Locations ABS - Di Page 4294 Part 2 Of 3 Page 1576 Engine Page 2846 ^ 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 3616 R/B No.2 Part-2 Engine Room Fuse Details J/B No.1 Part-1 Page 2730 Step 3 - 4 Testing and Inspection Control Module: Testing and Inspection Terminals Of ECM/Pinouts Page 737 El - Un Page 1540 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 361 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 to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 2808 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 1261 CAUTION: - Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45014 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3 (See step 1). h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. 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 fuel hose connections, fuel pump, fuel filter and fuel pressure regulator k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kgf/sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. Page 2375 Catalytic Converter: Testing and Inspection ON-VEHICLE INSPECTION 1. INSPECT 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 the protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT TWC HEAT INSULATOR a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and heat insulator. Page 3735 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Locations Air Flow Meter/Sensor: Locations Engine Page 4047 Glossary Of Terms And Symbols Part 2 Page 4492 1. INSTALL NEW BEARING a. Using 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 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 the oil seal lip with MP grease. 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/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. Pre runner: 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 2902 Fluid - A/T: Fluid Type Specifications Automatic transmission fluid ................................................................................................................ ................................................................. ATF T-IV Gap Spark Plug: Specifications Gap Gap Spark Plug Gap 1.1 mm (0.043 in.) Page 1625 Page 2626 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 1004 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 1848 Engine Coolant Temperature (ECT) Sensor Page 2571 Engine Locations Overdrive Switch: Locations Automatic Transmission Locations Fuse: Locations R/B No.2 - Engine Compartment Left Page 1682 Engine Locations Control Assembly: Locations Instrument Panel Page 1127 Vehicle Lift And Support Locations Part 2 Page 3782 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Collision / Non-Collision Inspections Clockspring Assembly / Spiral Cable: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION INSPECT SUPPLEMENTAL RESTRAINT SYSTEM a. Do a diagnostic system check. * 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 INSPECT SUPPLEMENTAL RESTRAINT SYSTEM a. Do a diagnostic system check. * b. Do a visual check which includes the following items wit 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 harness, 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. Locations Switch: Locations A/C - Ho Locations Air Flow Meter/Sensor: Locations Engine Page 4143 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. Page 3277 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 339 Bu - VSV (Except Double Cab) Removal and Installation Alternator: Service and Repair Removal and Installation Generator REMOVAL Page 3937 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 1497 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. On-Vehicle Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection On-Vehicle Inspection THERMISTOR ON-VEHICLE INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector from the thermistor. b. Using an ohmmeter, check that there is continuity between the terminals. Standard resistance: 1,500 ohms at 25 °C (77 °F) If resistance has no continuity, proceed next inspection. Page 186 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 787 When the cross camber or caster of the front wheel alignment is large it can cause vehicle pulling. If the cross camber or caster is within the specified range (30' or less), noticeable vehicle pulling will not occur due to side-to-side differences in camber or caster. NOTE On a flat road, if the cross camber or caster is 30' or less and the steering wheel is held without exerting steering effort for 109 yards (100 m) when driving at 62 mph (100 km/h), the alignment-induced drift distance is approximately 1.64 feet (0.5 m). 2. Relationship Between Tire Characteristics and Vehicle Pulling to One Side When radial tires are rotating they have the characteristic of generating force in the lateral direction between the tire and the road surface. This lateral force is comprised of two factors: ^ Ply-steer which changes direction according to the rotation direction of the tires. ^ Conicity which is generated in a fixed direction regardless of the tire rotation direction. If these lateral forces are too strong vehicle pulling will occur. A. Ply-Steer Lateral force due to ply-steer is produced by the construction of the belts inside the tire tread. With radial tires the wire of the belt is slanted as shown in the illustration below. Thus it is in the lateral direction that tire tread easily changes shape (stretches) and lateral force is generated between the tire and the road surface in the lateral direction. Lateral force from ply-steer prevents vehicle drift caused by road slant, so in many cases lateral force to the left is provided to compensate for road slant to the right. B. Conicity Conicity is lateral force resulting from uneven formation of the left and right sides of the tire. The direction the lateral force is exerted depends on the hardness of the side walls and the difference in height between the left/right sides of the tire. NOTE ^ In the case of vehicle pulling caused by tires, the lateral force which is exerted as a result of conicity has the greatest effect. On a flat road, Page 1303 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). Page 2685 Engine Page 4694 Evaporator Temperature Sensor / Switch: Service and Repair THERMISTOR REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE THERMISTOR a. Disconnect the connector clamp. b. Pull out the thermistor from evaporator. INSTALLATION Installation is in the reverse order of removal. 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. Locations ABS - Di Page 202 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 1535 Step 1 - 3 Tools and Equipment Valve Spring: Tools and Equipment Valve Spring Depressor AST tool# TOY 160 Valve Spring Depressor used for Toyota Engines. - Made of Aluminum toyota valve springs depressor Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2493 If operation is as not specified, replace the fuel pump and/or set plate. b. Connect the fuel pump connector. c. Install the floor service hole cover with the 3 screws. d. Connect the LH rear seat cushion. Page 2063 CHART 25 Page 2207 Step 6(Continued) - 8 Step 9 INSPECTION PROCEDURE Page 1316 Part 3 Of 3 REMOVAL 1. REMOVE TIMING BELT 2. REMOVE WATER INLET AND THERMOSTAT 3. DISCONNECT NO.2 OIL COOLER HOSE FROM WATER PUMP 4. REMOVE WATER PUMP a. Remove the 7 bolts. b. Pry out the water pump. INSPECTION 1. INSPECT WATER PUMP a. Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the 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 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 3543 Id - Wi Page 573 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Page 2760 El - Un Page 2997 Automatic Transmission Testing and Inspection Leak Detection Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. HINT: Near the fuel tank. 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. Connect a voltmeter to terminals PTNK and E2, and measure the output voltage. Voltage: 3.0 - 3.6 V Page 869 - Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects, as shown in the illustrations, check these points: 1. Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation. 2. If the belt teeth are cracked or damaged, check to see if either camshaft is locked. 3. 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. 4. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. 5. If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation, 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. 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. Page 1948 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 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 3894 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 484 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 3963 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 Page 3054 Bu - VSV (Double Cab) Page 1109 1. INSTALL NEW BEARING a. Using 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 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 the oil seal lip with MP grease. 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/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. Pre runner: 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 3201 Step 1 - 2 Page 1857 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 3303 Brake Pedal Assy: Diagrams BRAKE PEDAL W/ RELATED COMPONENTS Page 2864 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 38 Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2562 Engine Testing and Inspection Leak Detection Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. HINT: Near the fuel tank. 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. Connect a voltmeter to terminals PTNK and E2, and measure the output voltage. Voltage: 3.0 - 3.6 V Page 3299 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, 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 Page 3945 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 1241 17. SET NO.1 CYLINDER AT TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt to the crankshaft. b. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. c. Check that the timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°). d. Remove the crankshaft pulley bolt. 18. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. 19. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. 20. REMOVE TIMING BELT 21. REMOVE RH CAMSHAFT TIMING PULLEY a. Using SST, loosen the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) b. Remove the bolt, knock pin and timing pulley. Page 3995 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Page 2829 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). 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 4432 1. Align the leaf holes and secure the leaves with a vise. 2. Install the spring center bolt. Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.) e. Bend the spring clip. Using a hammer, bend the spring clip into the position. 4. 2WD (except pre runner): REPLACE SPRING BUMPER a. Remove the 2 bolts and spring bumper. b. Install the 2 bolts and spring bumper. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. Page 1105 7. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using 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 Installation is in the reverse order of removal. HINT: After installation, bleed the brake system, check the front wheel alignment and ABS speed sensor signal. Locations Id - Wi Recall 05V225000: Front Lower Ball Joint Replacement Ball Joint: Recalls Recall 05V225000: Front Lower Ball Joint Replacement MAKE/MODELS: Model/Build Years: Toyota/4 Runner 2001-2002 Toyota/Sequoia 2002-2004 Toyota/Tacoma 2001-2004 Toyota/Tundra 2002-2004 MANUFACTURER: Toyota Motor North America, Inc. NHTSA CAMPAIGN ID NUMBER: 05V225000 RECALL DATE: May 06, 2005 COMPONENT: Suspension: Front: Control Arm: Lower Ball Joint POTENTIAL NUMBER OF UNITS AFFECTED: 774856 SUMMARY: On certain sport utility vehicles, due to a manufacturing issue in the front suspension lower ball joint, there is a possibility that the surface of the ball of the joint may have been scratched. The ball joint may eventually experience excessive wear and looseness, resulting in increased steering effort. CONSEQUENCE: The lower ball joint may separate from the knuckle causing loss of steering control and a crash could occur with prior warning. REMEDY: Dealers will replace the front suspension lower ball joints. The recall is expected to begin on July 15, 2005. Owners should contact Toyota at 1-800-331-4331. NOTES: Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Locations Knock Sensor: Locations Id - Wi Page 2223 Engine Locations Control Unit: Locations Instrument Panel Page 2098 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 4147 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 2030 Applicable Vehicles Page 1979 Engine Control Module (ECM) Page 212 Engine Control Module: Locations Instrument Panel Page 3890 Glossary Of Terms And Symbols Part 2 Page 2149 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. Description and Operation Data Link Connector, A/T: Description and Operation Inspect the DLC3 3RZ-FE: The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 5VZ-FE: 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 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 3327 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 3973 J/B No.1 Inner Circuit Page 1354 Radiator: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No.1 fan shroud. Page 2429 r. Stop the engine. s. 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. t. 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 u. Remove the other union bolt 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks 3. INSPECT FUEL PUMP RESISTANCE a. Pull up the LH rear seat cushion. b. Remove the floor service hole cover with the 3 screws. c. Disconnect the fuel pump connector. d. Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 0.3 Ohm at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or set plate. 4. INSPECT FUEL PUMP OPERATION a. Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operations. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. Page 3363 a. Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with or move the load sensing spring. b. In this position, check the rear brake pressure. 2WD (except pre runner) 4WD and pre runner If the measured value is not within the standard, replace the valve body. Page 1666 Oxygen Sensor: Locations A/C - Ho Page 96 J/B No.1 Inner Circuit Specifications Idle Speed: Specifications Idle speed ............................................................................................................................................ ............................................................. 700 ± 50 rpm Page 1930 Page 3892 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 2205 Step 1 - 3 Page 2607 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 2185 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 4548 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 2295 CHART 12 CHART 13 Page 3796 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 813 If operation is as not specified, replace the fuel pump and/or set plate. b. Connect the fuel pump connector. c. Install the floor service hole cover with the 3 screws. d. Connect the LH rear seat cushion. Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation REMOVAL 1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2. DISCONNECT WIRE HARNESS FROM BRACKET 3. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. Locations Throttle Position Sensor: Locations Id - Wi Locations Brake Switch (Cruise Control): Locations Cruise Control System (w/ETCS-i) Page 2412 1. Blow air the intake chamber side when lift up the inside valve, and check that there is a strong resistance to air flow. If operation is not as specified, replace the PCV valve. f. Remove the clean hose from the PCV valve. g. Reinstall the PCV valve. 2. INSPECT HOSES, CONNECTIONS AND GASKETS Visually check for cracks, leaks or damage. Page 3604 "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 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. "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 3135 ^ 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." Page 4054 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 3736 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 553 CHART 23 Page 3750 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 3756 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Page 523 Applicable Vehicles Page 2666 Engine Page 1815 HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Page 1307 HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Page 1075 J/B No.3 Inner Circuit Page 4195 By performing this operation, it can be checked whether the left or right tire exerts a stronger lateral force. Either tire can be reversed. Shown here is an example of the left tire reversed. If Vehicle Pull Is Eliminated: Repair Is Now Complete. The lateral force generated by the left and right front tires is virtually the same so the lateral force is neutralized and the vehicle travels straight ahead. The repair operation is now completed. B. Rotate the larger lateral force front tire with the rear tire and check the change in the vehicle pulling. NOTE By shifting the front tire with the larger lateral force to the rear, the vehicle pulling level is usually reduced. If Vehicle Is Still Pulling: Go to step 3C. If Vehicle Pull Is Eliminated: Repair Is Now Complete. C. Adjust cross camber to eliminate vehicle pulling. HINT If the tires are placed in the positions they were in during tire rotation when the least amount of vehicle pulling occurred, wheel alignment can be performed with a minimal amount of adjustment. NOTE ^ Keep the cross camber within 10 or less. ^ Keep the camber of each wheel within specifications (+/-45' of center value). ^ If adjustment exceeds the specifications, uneven tire wear will result. 4. Camber Adjustment Method. ^ After the camber has been adjusted, inspect the toe-in. Locations Relay Box: Locations R/B No.2 - Engine Compartment Left Page 1495 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 177 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 1108 a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using 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/ spacer. 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 2798 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 4072 Relay Box: Connector Views J/B No.1 - Lower Finish Panel Page 3314 a. Prepare the wooden plate to hold the pistons. 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 seals from the cylinder. INSPECTION 1. MEASURE PAD LINING THICKNESS Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) 2. MEASURE DISC THICKNESS Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) 3. MEASURE DISC RUNOUT a. Tighten the disc with the 3 hub nuts. b. 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 bearing play is within the specification. 4. IF NECESSARY, ADJUST DISC RUNOUT a. Remove the hub nuts and disc. Reinstall the disc rotating 1/6 of a turn from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. b. Repeat (a) until the disc has been installed on the 4 remaining hub position. If the minimum runout recorded in (a) and (b) is less than the maximum disc runout, install the disc in that position. If the minimum runout recorded in (a) and (b) 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 base glycol grease to the parts indicated by the arrows. Page 3858 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Page 3083 Part 2 Of 2 DISASSEMBLY 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. Pre runner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 3. Pre runner: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER Page 3790 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Interior - Dash Pad Rattles Wiring Harness: Customer Interest Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Page 1376 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 to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 2202 Terminals Of ECM/ Pinouts Part 2 Page 531 Page 302 Power Window Relay: Testing and Inspection INSPECT POWER MAIN (Marking : PWR) RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 3368 Brake Proportioning/Combination Valve: Service and Repair Disassembly and Assembly LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) DISASSEMBLY 1. REMOVE VALVE BRACKET a. Remove the nut, bolt and 2 plate washers. b. 2WD (except pre runner): Remove the 2 nuts and flexible hose bracket, and remove the valve bracket and set plate from the valve body. Testing and Inspection ABS Light: Testing and Inspection ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this 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 output the DTC. Wiring Diagram Page 1703 Bu - VSV (Except Double Cab) Capacity Specifications Refrigerant: Capacity Specifications Capacity 600 ± 50 g (21.16 ± 1.76 oz.) Page 2298 CHART 16 CHART 17 Page 3683 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. Page 556 CHART 25 Page 2851 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 1262 r. Stop the engine. s. 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. t. 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 u. Remove the other union bolt 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks 3. INSPECT FUEL PUMP RESISTANCE a. Pull up the LH rear seat cushion. b. Remove the floor service hole cover with the 3 screws. c. Disconnect the fuel pump connector. d. Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 0.3 Ohm at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or set plate. 4. INSPECT FUEL PUMP OPERATION a. Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operations. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. Page 3898 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 2605 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Page 1802 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Page 241 Circuit Opening Relay Page 2497 Engine Page 4295 Part 3 Of 3 REMOVAL HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB NOTICE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable. 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD Page 3479 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 900 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 4373 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 2262 Engine Page 4166 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Page 2336 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Page 1587 4. REINSTALL NO.2 TIMING BELT COVER Page 2122 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 88 "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 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. "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 4775 Clockspring Assembly / Spiral Cable: Service and Repair Removal and Installation Steering Wheel Pad And Spiral Cable HINT: for steps 1 - 4 refer to Steering Column. REMOVAL 1. REMOVE STEERING WHEEL PAD 2. REMOVE STEERING WHEEL 3. REMOVE UPPER AND LOWER COVERS 4. REMOVE SPIRAL CABLE Page 2601 Throttle Body (w/ETCS-i) 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 3348 a. Prepare the wooden plate to hold the pistons. 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 seals from the cylinder. INSPECTION 1. MEASURE PAD LINING THICKNESS Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) 2. MEASURE DISC THICKNESS Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) 3. MEASURE DISC RUNOUT a. Tighten the disc with the 3 hub nuts. b. 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 bearing play is within the specification. 4. IF NECESSARY, ADJUST DISC RUNOUT a. Remove the hub nuts and disc. Reinstall the disc rotating 1/6 of a turn from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. b. Repeat (a) until the disc has been installed on the 4 remaining hub position. If the minimum runout recorded in (a) and (b) is less than the maximum disc runout, install the disc in that position. If the minimum runout recorded in (a) and (b) 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 base glycol grease to the parts indicated by the arrows. 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 Locations A/C - Ho Page 4389 Ball Joint: Diagrams Upper Part 1 Of 2 Page 2197 El - Un Page 3857 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. 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) Specifications Brake Caliper: Specifications Front disc brake caliper x Flexible hose ............................................................................................................................... 30 Nm (310 kgf-cm, 22 ft. lbs.) Page 89 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 3595 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 3814 J/B No.1 - Lower Finish Panel Page 1717 Engine Specifications Exhaust Manifold: Specifications Exhaust manifold Warpage Maximum ............................................................................................................................................. .................................... 1.00 mm (0.0394 inch) Exhaust manifold x Cylinder head ........................................................................................................................................ 40 Nm (400 kgf-cm, 30 ft. lbs.) Exhaust manifold heat insulator x Exhaust manifold ............................................................................................................ 8 Nm (80 kgf-cm, 71 inch lbs.) Exhaust crossover pipe x Exhaust manifold ......................................................................................................................... 45 Nm (450 kgf-cm, 33 ft. lbs.) Page 3222 El - Un Page 4083 J/B No.1 - Lower Finish Panel Page 1904 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 1895 ^ 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 85 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 2680 4. REINSTALL NO.2 TIMING BELT COVER Page 3410 Terminals Of ECU / Pinouts Part 2 Page 4238 c. Connect SST, as shown. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check that the valve of the SST is in the open position. d. Bleed the power steering system. e. Start the engine and run it at idle. f. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) g. With the engine idling, close the valve of the SST and observe serve 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. h. With the engine idling, open the valve fully. i. 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. Locations Vehicle Speed Sensor: Locations Id - Wi Page 1966 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 4040 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 2677 Camshaft Position Sensor w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 217 Engine Control Module: Connector Views Terminals Of ECM/ Pinouts Part 1 Page 2129 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 3665 J/B No.1 Inner Circuit 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. Locations Id - Wi Page 176 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 1965 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 Acceleration/Deceleration Sensor: Locations ABS - Di Page 3902 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 4363 Locations A/C - Ho Page 1239 4. DISCONNECT PS PUMP FROM ENGINE a. Disconnect the 2 PS air hoses from the air intake chamber and resonator. b. Remove the bolt holding the PS pressure tube clamp to the frame. c. Remove the drive belt. d. Remove the bolt and nut, and disconnect the PS pump from the engine. 5. DISCONNECT A/C COMPRESSOR FROM ENGINE a. Disconnect the A/C compressor connector. b. Remove the drive belt. c. Remove the 4 bolts, and disconnect the A/C compressor from the engine. 6. LOOSEN FAN WITH FLUID COUPLING AND FAN PULLEYS 7. REMOVE DRIVE BELT FOR GENERATOR 8. REMOVE NO.2 FAN SHROUD 9. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS 10. REMOVE A/C COMPRESSOR BRACKET Remove the 5 bolts and A/C compressor bracket. 11. REMOVE OIL DIPSTICK AND GUIDE Remove the bolt, oil dipstick, guide and O-ring. 12. REMOVE NO.2 TIMING BELT COVER a. Disconnect the 4 high-tension cord clamps from the timing belt cover. b. Remove the 6 bolts and timing belt cover. c. Disconnect the camshaft position sensor connector. Locations Throttle Position Sensor: Locations Id - Wi Page 2033 A/F and 02 Sensor Identification Service and Repair Universal Joint: Service and Repair SPIDER BEARING REPLACEMENT NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. PLACE MATCHMARKS ON SHAFT AND YOKE 2. TMC made: REMOVE SNAP RING a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using 2 screwdrivers, remove the 4 snap rings from the grooves. 3. DANA made: REMOVE SNAP RING a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using needle nose pliers, remove the 4 snap rings from the grooves. 4. REMOVE SPIDER BEARING a. Using SST, push out the bearing from the propeller shaft. 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 propeller shaft with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. Page 2566 Fuel Pump Relay: Testing and Inspection EFI Main Relay INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. Page 529 ^ 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: Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant oil to be added when replacing components. Evaporater ........................................................................................................................................... .................................................... 40 cc (1.4 fl. oz.) Receiver/dryer ..................................................................................................................................... ................................................... 20 cc (.071 fl. oz) Condensor ........................................................................................................................................... .................................................... 40 cc (1.4 fl. oz.) 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 1927 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 805 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. 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, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). Page 3889 Glossary Of Terms And Symbols Part 1 Page 3501 Alternator: Testing and Inspection INSPECTION 1. INSPECT VOLTAGE REGULATOR a. Using an ohmmeter, check the continuity between terminals F and B. Standard: When the positive and negative poles between terminals F and B are exchanged, there is continuity in one way but no continuity in another way. If the continuity is not as specified, replace the regulator. b. Using an ohmmeter, check the continuity between terminals F and E. Standard: When the positive and negative poles between terminals F and E are exchanged, there is continuity in one way but no continuity in another way. If the continuity is not as specified, replace the regulator. 2. INSPECT ROTOR a. Check the 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. Page 4599 4. INSPECT DIMMING OPERATION a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 7, 25 while press the switch. b. Push the REC button in and then check that the indicator lights up. c. Connect the positive (+) lead from the battery to terminal 15 and then check that the indicator dims. If operation is not as specified, replace the switch circuit board. 5. INSPECT A/C INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 10, 25. b. Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch circuit board. 6. INSPECT DIMMING OPERATION a. Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 10, 25 while press the switch b. Push the A/C button in and then check that the indicator lights up. c. Connect the positive (+) lead from the battery to terminal 20 and then check that the indicator dims. If operation is not as specified, replace the switch circuit board. 7. INSPECT SWITCH CONTINUITY Page 4660 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 Locations Id - Wi Page 4619 8. 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 3940 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 1841 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Page 1911 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 4201 Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) VZN170L-PRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 68 mm (2.68 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -20 mm (-0.79 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 69 mm (2.72 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -17 mm (-0.67 inch) RZN171L-CRMDKAB Normal Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... ......................................... 39 mm (1.54 inch) P265/70R16 111S Rear: C*3 - D*4 .................................................................................................................................... ....................................... -44 mm (-1.73 inch) Tire size: P265/70R16 111T Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -43 mm (-1.69 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 52 mm (2.05 inch) Rear C*3 - D*4 ............................................................ ................................................................................................................ -38 mm (-1.50 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -38 mm (-1.50 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) RZN171L-CRPDKAB Normal Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -43 mm (-1.69 inch) Tire size: P265/70R16 111S Front: A*1. B*2 ..................................................................................................................................... ......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ............................................................ ............................................................................................................... -44 mm (-1.73 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -38 mm (-1.50 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) RZN191L-TRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ............................................................................................................... -46 mm (-1. 18 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -42 mm (-1.65 inch) Tire size: P265/70R16 111S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -43 mm (-1.69 inch) VZN195L-CRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -46 mm (-1.81 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 47 mm (1.85 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -41 mm (-1.61 inch) Heavy-duty leaf spring Page 2860 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 3502 b. Check the 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. c. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. d. Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. 3. INSPECT STATOR (DRIVE END FRAME) a. Check the 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. Page 4170 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Page 4360 Page 3472 Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY (Marking: ST) 2. INSPECT STARTER RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. Page 2068 Page 3903 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 3908 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 1688 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 179 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 3768 Relay Box: Electrical Diagrams J/B No.1 Inner Circuit Page 1067 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 2304 Page 2691 El - Un Page 1528 Engine Control Module (ECM) Specifications Compression Check: Specifications Compression pressure at 250 rpm STD .......................................................................................................................................................... 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum .......................................................................... ..................................................................................... 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder ......................................................................................................... 100 kPa (1.0 kgf/cm2, 15 psi) or less Page 2430 If operation is as not specified, replace the fuel pump and/or set plate. b. Connect the fuel pump connector. c. Install the floor service hole cover with the 3 screws. d. Connect the LH rear seat cushion. Page 1681 Engine Page 3661 J/B No.1 - Lower Finish Panel Page 1799 Spark Plug: Specifications Torque Torque Spark Plug Torque 13 ft.lbf Page 2833 Page 4816 Air Bag Control Module: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor assembly and judges whether the SRS must be activated or not and diagnosis system malfunctions. Specifications Parking Brake Lever: Specifications Parking brake lever travel at 196 N (20 kgf-cm, 44.1 lbs.) ............................................................................................................................... 12 - 18 clicks Page 1036 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. 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 the wire routing is shown in square brackets [ ]. 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 561 Page 181 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 1890 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 4424 a. Remove the 4 bracket set bolts and stabilizer bar with the cushions and brackets. Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.) b. Remove the 2 brackets and cushions from the stabilizer bar. INSPECTION 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 each 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 Installation is in the reverse order of removal. Page 1893 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 3553 Starter (Part 2) REMOVAL REMOVE STARTER Page 64 Abbreviations Page 227 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 1453 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 3760 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Locations Fuel Pump Relay: Locations ABS - Di Page 4041 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 3085 1. INSTALL NEW BEARING a. Using 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 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 the oil seal lip with MP grease. 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/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. Pre runner: 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. Tools and Equipment 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 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 4737 Air Bag Control Module: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor assembly and judges whether the SRS must be activated or not and diagnosis system malfunctions. Page 4196 ^ The method of camber adjustment differs for different models, so please refer to the Repair Manual of the vehicle involved. (The information below are samples from the Sienna Repair Manual.) A. Remove the front wheels and ABS speed sensor clamp. B. Remove the two nuts on the lower side of the shock absorber. C. Coat the threads of the nuts with engine oil. D. Temporarily install the two nuts. E. Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. F. Tighten the nuts. Torque: 210 N*m (2150 kgf*cm, 155 ft*lbf) G. Install the front wheels. Torque: 104 N*m (1050 kgf*cm, 77 ft*lbf) H. Check the camber. Locations Id - Wi Page 2015 Engine Page 4652 b. Disconnect the water hoses from the heater radiator pipes. 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 the position, as shown in the illustration. 4. REMOVE INSTRUMENT PANEL AND REINFORCEMENT 5. REMOVE DEFROSTER NOZZLE AND HEATER TO REGISTER DUCT 6. DISCONNECT AIR OUTLET SERVOMOTOR CONNECTOR 7. DISCONNECT AIR MIX SERVOMOTOR CONNECTOR 8. REMOVE HEATER UNIT Remove the 2 bolts, nut and heater unit. INSTALLATION Installation is in the reverse order of removal. Page 4684 Blower Motor Relay: Testing and Inspection HEATER MAIN RELAY INSPECTION INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Specifications Brake Bleeding: Specifications Fluid Type AE J1703 or FMVSS No.116 DOT3 Page 1096 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 Locations Camshaft Position Sensor: Locations A/C - Ho Page 4254 If necessary, replace the valve. NOTICE: Install a new valve with the same inscribed mark as the old one. 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 specification, replace the spring. REPLACEMENT REPLACE OIL SEAL a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the bushing of the front housing. b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00330), 09950-70010 (09951-07100) NOTICE: Make sure to install the oil seal facing the correct direction. REASSEMBLY Specifications Power Steering Fluid: Specifications Fluid ..................................................................................................................................................... ............................................ ATF DEXRON II or III Page 4563 Blower Motor Relay: Testing and Inspection HEATER MAIN RELAY INSPECTION INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Locations Ignition Switch: Locations Ignition Switch And Key Unlock Warning Switch Locations Leak Detection Solenoid: Locations Id - Wi 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 Positive Crankcase Ventilation: Testing and Inspection INSPECTION 1. INSPECT PCV VALVE a. Remove the PCV valve. 1. Disconnect the PCV hose from the PCV valve. 2. 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 cover 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 air intake chamber side, and check that air passes through with difficulty. d. Remove the clean hose from the PCV valve e. Reinstall the PCV valve. Page 2062 CHART 24 Page 1396 Part 3 Of 3 REMOVAL 1. REMOVE TIMING BELT 2. REMOVE WATER INLET AND THERMOSTAT 3. DISCONNECT NO.2 OIL COOLER HOSE FROM WATER PUMP 4. REMOVE WATER PUMP a. Remove the 7 bolts. b. Pry out the water pump. INSPECTION 1. INSPECT WATER PUMP a. Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the 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 Page 4769 3. 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. 4. 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. Page 3969 J/B No.1 - Lower Finish Panel Page 4046 Glossary Of Terms And Symbols Part 1 Page 2166 ^ 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 1762 Knock Sensor Part 2 Removal and Installation Control Assembly: Service and Repair Removal and Installation HEATER CONTROL ASSEMBLY Heater Control Assembly (Part 1) Capacity Specifications Coolant: Capacity Specifications Fluid capacity M/T ...................................................................................................................................................... ........................... 9.7 L (10.3 US qts, 8.5 Imp. qts) A/T ....................................................................... .......................................................................................................... 9.5 L (10.0 US qts, 8.4 Imp. qts) Page 4539 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Page 2080 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Page 1729 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Page 3256 Step 1 - 3 INSPECTION PROCEDURE Troubleshooting in accordance with the chart for each trouble symptom. Page 2107 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. Locations Knock Sensor: Locations Id - Wi 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 temperature sender gauge. Page 1669 Engine Page 1897 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 1054 Page 2823 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 90 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 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 Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left Locations Evaporative Vapor Pressure Sensor: Locations Bu - VSV (Double Cab) Page 475 Engine Page 853 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). Page 4418 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 3072 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 1512 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: Locations Intake Air Temperature Sensor: Locations Engine Page 1041 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 2866 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 3834 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Page 3856 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. Page 4620 Evaporator Case: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor. 2. SEPARATE UPPER AND LOWER UNIT CASES a. Using a knife, cut off the each packing. b. Remove the 3 clips and 3 screws. c. Separate the upper and lower unit case. 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 THERMISTOR a. Disconnect the connector clamp. b. Pull out the thermistor from evaporator. 5. REMOVE EXPANSION VALVE Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve and evaporator and tubes. Page 1931 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 3964 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 4145 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Page 1642 CHART 10 Locations Transmission Control System Relay: Locations Instrument Panel Page 2016 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 2872 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 768 Rear Left Switch (Window lock) Rear Right Switch (Window Unlock) Rear Right Switch (Window lock) 4 Door: INSPECT POWER WINDOW MASTER SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT FRONT POWER WINDOW CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Locations Leak Detection Valve: Locations Engine Page 1021 J/B No.3 Inner Circuit Page 130 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 3655 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 Page 559 Page 3701 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Page 2799 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 1660 Testing and Inspection Evaporator Core: Testing and 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 Repair as necessary. Locations Fuse Block: Locations R/B No.2 - Engine Compartment Left Page 499 Engine Page 2070 CHART 29 Specifications Brake Fluid: Specifications Brake fluid type ......................................................................................................................................................... SAE J1703 or FMVSS No.116 DOT3 Page 4301 1. REMOVE 2 TURN PRESSURE TUBES a. Using SST, remove the 2 turn pressure tubes. SST 09023-38200 b. Remove the 2 union seats from the rack housing. c. Remove the 2 union seats from the control valve housing. 2. SECURE PS GEAR ASSEMBLY IN VISE Using SST and 2 bolts, 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 RH AND LH TIE ROD ENDS AND LOCK NUTS a. Place matchmarks on the tie rod end and rack end. b. Loosen the look nut, and remove the tie rod end and lock nut. c. Employ the same manner described above to the other side. 4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS a. Remove the screw and loosen the clamp. b. Remove the clip, rack boot and clamp. c. Employ the same manner described above to the other side. NOTICE: Be careful not to damage the boot. Locations Transmission Temperature Sensor/Switch: Locations A/C - Ho Page 1398 Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) 2. CONNECT NO.2 OIL COOLER HOSE 3. INSTALL THERMOSTAT AND WATER INLET 4. INSTALL TIMING BELT Diagrams Wheel Hub: Diagrams Part 1 Of 2 Page 1170 Intake: N = T - (A - 0.18 mm (0.007 inch)) Page 4791 1. REMOVE BATTERY a. Remove the bolt and battery clamp. b. Remove the battery and battery carrier. 2. REMOVE FRONT AIRBAG SENSOR RH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 nuts and front airbag sensor RH. 3. REMOVE FRONT AIRBAG SENSOR LH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 bolts and front airbag sensor LH. INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR LH AND RH 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 Page 2608 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Page 4443 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 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 SHOCK ABSORBER a. Remove the 2 rear shock absorber set bolts. Torque: 2WD: 26 Nm (260 kgf-cm, 19 ft. lbs.) 4WD and pre runner: 71 Nm (730 kgf-cm, 53 ft. lbs.) b. Remove the rear shock absorber. INSPECTION INSPECT SHOCK ABSORBER Page 1601 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Diagrams Suspension Spring ( Coil / Leaf ): Diagrams REAR LEAF SPRING REPLACEMENT W/ RELATED COMPONENTS Page 3383 Brake Master Cylinder: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE RESERVOIR a. Remove the set screw and pull out the reservoir. Torque: 1.5 Nm (15 kgf-cm, 13 inch lbs.) b. Remove the cap and strainer from the reservoir. 2. REMOVE 2 GROMMETS 3. PLACE CYLINDER IN VISE Locations Actuator: Locations Bu - VSV (Double Cab) Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM 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. Page 2427 Fuel Pressure: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See step 4). f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay, fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. 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 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections 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: Bracket deformation - Paint peeling off the bracket - Cracks, dents or chips in the case - Cracks, dents, chipping and scratches in the connector - 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/Initial Inspection and Diagnostic Overview Page 83 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Locations Page 2010 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Locations Instrument Panel Page 2863 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 3094 Drive/Propeller Shaft: Specifications Torque Specifications TORQUE SPECIFICATIONS Page 564 CHART 30 Page 155 ^ 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 2419 Engine Page 191 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 3557 Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf) for 1.4 kW 3.8 N.m (39 kgf.cm, 34 in.lbf) for 3.8 kW b. Remove the O-ring from the field frame. HINT: At the time of reassembly, please refer to the following items. 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. 5. REMOVE ARMATURE FROM FIELD FRAME REASSEMBLY Reassembly is in the reverse order of disassembly HINT: Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter. REPLACEMENT 1. REPLACE FRONT BEARING a. Using SST, remove the bearing. SST 09286-46011 b. Using a press, press in a new bearing. Page 798 Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -40 mm (-1.57 inch) Tire size: P265/70R16 111S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Front wheel P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ............................................. -39 mm (-1.54 inch) VZN195L-PRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 67 mm (2.64 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -23 mm (-0.91 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 68 mm (2.68 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -20 mm (-0.79 inch) RZN196L-CRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -46 mm (-1.81 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 48 mm (1.89 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -41 mm (-1.61 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) P265/70R16 111S Rear: C*3 - D*4 .................................................................................................................................... ....................................... -40 mm (-1.57 inch) Tire size: P265/70R16 111T Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) RZN196L-PRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 66 mm (2.60 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -23 mm (-0.91 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 77 mm (3.03 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -19 mm (-0.75 inch) ^ Camber ............................................................................................................................................. ............................ Right - left error: 30' (0.5°) or less RZN161L models ................................................................................................................................. ....................................... 0°18' ± 45'(0.3° ± 0.75°) VZN1701-models Except double cab models Normal ................................................................................................................................................. ................................ 0°18' ± 45' (0.3° ± 0.75°) Off-road package ....................................................... ........................................................................................................... 0°06' ± 45' (0.1° ± 0.75°) Double cab models Normal ................................................................................................................................................. ................................. -0°12' ± 45' (-0.2° 0.75°) Off-road package ....................................................... ........................................................................................................ -0°18' ± 45' (-0.3° ± 0.75°) RZN11711-models Normal ................................................................................................................................................. ................................. 0°18' ± 45' (0.3' ± 0.75°) Off-road package ....................................................... ........................................................................................................... 0°06' ± 45' (0.1° ± 0.75') RZN191L models ................................................................................................................................. ................................ 0°18' ± 45' (0.3° ± 0.75°) VZN195L models Except double cab models .................................................................................................................................................... 0°12' ± 45' (0.2° ± 0.75°) Double cab models Normal ................................................................................................................................................. .............................. -0°12' ± 45' (-0.2° ± 0.75°) Off-road package ....................................................... ........................................................................................................ -0°18' ± 45' (-0.3° ± 0.75°) VZN1961-models Except double cab models Normal ................................................................................................................................................. ................................ 0°18' ± 45' (0.3° ± 0.75°) Off-road package ....................................................... .......................................................................................................... 0° 12' ± 45' (0.2° ± 0.75°) Double cab models Normal ................................................................................................................................................. .............................. -0°12' ± 45' (-0.2° ± 0.75°) Off-road package ....................................................... ........................................................................................................ -0°30' ± 45' (-0.5° ± 0.75°) ^ Caster ............................................................................................................................................... .............................. Right-left error: 30' (0.5°) or less RZN161L-TRMDKAB Normal Tire size: P225/75R15 102S .............................................................................................................................................. 1°37' ± 45' (1.62° ± 0.75°) Tire size: P265/70R16 111S .............................................................................................................................................. 1°38' ± 45' (1.63° ± 0.75°) Page 4307 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 ring. b. Coat a new O-ring with power steering fluid and install it. c. Expand a new teflon ring with your fingers. NOTICE: Be careful not to over expand the ring. d. Coat the teflon ring with power steering fluid. e. Install the teflon ring to the rack, and settle it down with your fingers. 9. 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 over expand the teflon ring. c. Coat the teflon rings with power steering fluid. 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 2305 CHART 23 Page 2595 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Page 500 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Page 3791 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Page 4250 Part 2 Of 2 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Page 3008 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 222 Step 4 - 6 Page 3182 Bu - VSV (Except Double Cab) Page 185 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 1939 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 121 ^ 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 284 Terminals Of ECM/Pinouts Part 1 Terminals Of ECM/Pinouts Part 2 Page 1894 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. Locations Fuel Pump Relay: Locations ABS - Di Page 2922 Step 3 - 4 Page 953 Brake Bleeding: Service and Repair 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. 3. BLEED BRAKE LINE a. Connect the vinyl tube to the caliper or wheel cylinder bleeder plug. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic. b. Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. Page 1763 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 406 Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminal and the switch body in the ON position (switch pin released : opened door). b. Check that no continuity exists between terminal and the switch body in the OFF position (switch pin pushed in : closed door). If operation is not as specified, replace the switch. Page 486 4. REINSTALL NO.2 TIMING BELT COVER Page 1687 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Locations Relay Box: Locations R/B No.2 - Engine Compartment Left Page 3286 Wheel Speed Sensor: Diagrams Rear REAR SPEED SENSOR REPLACEMENT W/ RELATED COMPONENTS Page 654 Ignition 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. Page 3591 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Page 1648 CHART 18 CHART 19 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 1219 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: API grade SL Energy-Conserving or ILSAC multi-grade engine oil. 2. CHECK ENGINE OIL LEVEL After warming up the engine and then 5 minutes after the engine stop, the oil level should be between the low level and full level marks on the dipstick. If low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 3. REMOVE OIL PRESSURE SWITCH Using SST, remove the oil pressure switch. SST 09268-06021 4. INSTALL OIL PRESSURE GAUGE 5. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 6. CHECK OIL PRESSURE Oil pressure 7. REMOVE OIL PRESSURE GAUGE Circuit Opening Relay Fuel Pump Relay: Testing and Inspection Circuit Opening Relay INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and ohmmeter, check that there is continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 2150 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 3765 J/B No.1 - Lower Finish Panel Page 1039 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Locations Air Flow Meter/Sensor: Locations Engine 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 1521 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 1031 J/B No.1 - Lower Finish Panel Page 4808 Malfunction Lamp / Indicator: Testing and Inspection SRS WARNING LIGHT CHECK a. Turn the ignition switch to the 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 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". Locations Id - Wi On-Vehicle Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection On-Vehicle Inspection THERMISTOR ON-VEHICLE INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector from the thermistor. b. Using an ohmmeter, check that there is continuity between the terminals. Standard resistance: 1,500 ohms at 25 °C (77 °F) If resistance has no continuity, proceed next inspection. Removal and Installation Wheel Hub: Service and Repair Removal and Installation Part 1 Of 2 Page 4291 Part 3 Of 3 POWER STEERING GEAR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 3375 Using SST, disconnect the 5 brake lines from the ABS actuator. SST 9023-00100 Torque, 15 Nm (155 kgf-cm, 11 ft. lbs.) 3. REMOVE ABS ACTUATOR ASSEMBLY Remove the bolt, 2 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.) 4. REMOVE ABS ACTUATOR Remove the 4 nuts and the ABS actuator. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. Page 841 Spark Plug: Specifications Torque Torque Spark Plug Torque 13 ft.lbf Page 1932 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 3347 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 Page 3585 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Interior - Dash Pad Rattles Air Duct: All Technical Service Bulletins Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Locations Shift Interlock Relay: Locations Instrument Panel Page 4509 1. Place the servomotor arm in the 'WARM" position and measure the resistance between terminals 2 and 3. Please refer to the chart for specification. 2. Place the servomotor arm in the "COOL" position and measure the resistance between terminals 2 and 3. Please refer to the chart for specification. If resistance has no continuity, replace the servomotor. 3. INSTALL AIR MIX SERVOMOTOR a. Install the 3 screws and servomotor. b. Connect the servomotor connector. Page 2215 Engine 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 Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 2186 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 603 Engine Page 2384 2. Apply battery positive voltage across the terminals. 3. Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV 4. REMOVE VSV a. Disconnect the connector and 2 EVAP hoses. b. Remove the screw and VSV. Page 2290 CHART 5 CHART 6 Page 1524 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 1236 Part 2 Of 2 TIMING BELT REPLACEMENT W/ RELATED COMPONENTS Page 3727 J/B No.1 - Lower Finish Panel Details Page 3488 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. 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 Page 82 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Locations A/C - Ho Page 4167 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Page 4013 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Page 673 Impact Sensor: Locations Front Airbag Sensor Page 3980 J/B No.1 - Lower Finish Panel Details Locations El - Un Page 2274 Oxygen Sensor: 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 167 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 2694 Ignition 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. Page 3794 Step 1 Page 2320 Engine VSV For Canister Closed Valve (CCV) Leak Detection Solenoid: Testing and Inspection VSV For Canister Closed Valve (CCV) INSPECTION 1. REMOVE VSV 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. If there is no continuity, replace the VSV. 3. INSPECT 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 4. INSPECT VSV OPERATION a. Check that air flows from ports A to B Page 2252 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Page 3781 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 1318 Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) 2. CONNECT NO.2 OIL COOLER HOSE 3. INSTALL THERMOSTAT AND WATER INLET 4. INSTALL TIMING BELT Page 4381 Page 3099 1. 4WD: REMOVE FRONT PROPELLER SHAFT a. Place matchmarks on the propeller shaft and front differential flanges. b. Remove the 4 nuts, bolts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) c. Suspend the front side of the propeller shaft. d. Place matchmarks on the propeller shaft and transfer flanges. e. Remove the 4 nuts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) f. Remove the front propeller shaft. 2. REMOVE PROPELLER SHAFT (PRE RUNNER) AND REAR PROPELLER SHAFT (4WD) a. Place matchmarks on the propeller shaft, transmission (pre runner) and transfer (4WD) flanges. b. Remove the 4 nuts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) c. Place matchmarks on the propeller shaft and rear differential flanges. d. Remove the 4 nuts, bolts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) e. 3joint type: Remove the center support bearing 2 set bolts and 2 plates from the frame crossmember. Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.) Remove the propeller shaft. INSTALLATION Installation is in the reverse order of removal. Page 2741 El - Un Page 1610 Engine Specifications Piston Ring: Specifications Piston ring groove clearance No.1 ..................................................................................................................................................... .............. 0.040 - 0.080 mm (0.0016 - 0.0031 inch) No.2 ..................................................................... .............................................................................................. 0.030 - 0.070 mm (0.0012 - 0.0028 inch) Piston ring end gap STD No.1 ............................................................................................................................................................. 0.300 - 0.500 mm (0.0118 - 0.0197 inch) No.2 ............................................................................................................................................................. 0.400 - 0.600 mm (0.0157 - 0.0236 inch) Oil ....................................................................................... .......................................................................... 0.150 - 0.550 mm (0.0059 - 0.217 inch) Maximum No.1 ..................................................................................................................................................... .................................. 1.100 mm (0.0433 inch) No.2 ........................................................................... .............................................................................................................. 1.200 mm (0.472 inch) Oil .... .............................................................................................................................................................. ........................ 1.150 mm (0.0453 inch) Page 3154 El - Un Page 4630 Evaporator Temperature Sensor / Switch: Testing and Inspection Component Inspection INSPECTION 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 651 El - Un Page 3811 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 1668 Engine Page 4044 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 1752 El - Un Locations Transmission Mode Switch: Locations Automatic Transmission Page 113 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 2399 VSV For Pressure Switching Valve Page 3265 Anti-lock Brake System Page 1059 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 1472 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. 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 2325 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Page 4575 Compressor And Magnetic Clutch Page 1761 Knock Sensor Part 1 Page 3194 Bu - VSV (Except Double Cab) Locations Brake Proportioning/Combination Valve: Locations LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Air-Fuel Ratio (A/F) Sensor Oxygen Sensor: Testing and Inspection Air-Fuel Ratio (A/F) Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT If the resistance is not as specified, replace the sensor Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 1203 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. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil dipstick. c. Remove the oil drain plug and drain the oil into a container. 2. REPLACE OIL FILTER a. Using SST, remove the oil filter (located on left side of the cylinder block) SST 09228-07501 b. Clean the filter contact surface on the filter mounting c. Apply clean engine oil to the gasket of a new oil filter d. Tighten the filter by hand until the gasket contacts the seat of the filter mounting. Then using SST, give it an additional 3/4 turn to seat the filter. SST 09228-07501 3. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. b. Fill the engine with new oil. Oil capacity c. Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE LEVEL Page 3664 Fuse Block: Electrical Diagrams J/B No.1 Inner Circuit Page 1584 Camshaft Position Sensor Page 4499 Wheel Fastener: Service and Repair Rear REPLACEMENT 1. REMOVE REAR WHEEL AND BRAKE DRUM 2. REMOVE REAR HUB BOLT Using SST and a brass bar or an equivalent, remove the hub bolt. SST 09650-17011 3. 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. 4. INSTALL BRAKE DRUM AND REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 568 Engine Page 2280 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 3217 El - Un Page 2903 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. 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) Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Engine Control Module -- Go to Powertrain Management Diagrams. Page 865 4. DISCONNECT PS PUMP FROM ENGINE a. Disconnect the 2 PS air hoses from the air intake chamber and resonator. b. Remove the bolt holding the PS pressure tube clamp to the frame. c. Remove the drive belt. d. Remove the bolt and nut, and disconnect the PS pump from the engine. 5. DISCONNECT A/C COMPRESSOR FROM ENGINE a. Disconnect the A/C compressor connector. b. Remove the drive belt. c. Remove the 4 bolts, and disconnect the A/C compressor from the engine. 6. LOOSEN FAN WITH FLUID COUPLING AND FAN PULLEYS 7. REMOVE DRIVE BELT FOR GENERATOR 8. REMOVE NO.2 FAN SHROUD 9. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS 10. REMOVE A/C COMPRESSOR BRACKET Remove the 5 bolts and A/C compressor bracket. 11. REMOVE OIL DIPSTICK AND GUIDE Remove the bolt, oil dipstick, guide and O-ring. 12. REMOVE NO.2 TIMING BELT COVER a. Disconnect the 4 high-tension cord clamps from the timing belt cover. b. Remove the 6 bolts and timing belt cover. c. Disconnect the camshaft position sensor connector. Page 1063 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 4110 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 588 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Page 2360 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 4439 2. DISCONNECT SHOCK ABSORBER FROM LOWER SUSPENSION ARM a. Remove the shock absorber lower nut and washer. NOTICE: Do not remove the bolt. Torque: 135 Nm (1,400 kgf-cm, 101 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. b. With lowering the lower suspension arm, 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. Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. Disassembly and Reassembly Page 4085 Engine Compartment Instrument Panel Locations Locations Fuel Pump Relay: Locations ABS - Di Air-Fuel Ratio (A/F) Sensor Oxygen Sensor: Testing and Inspection Air-Fuel Ratio (A/F) Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT If the resistance is not as specified, replace the sensor Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 2381 Engine Specifications Wheel Fastener: Specifications Wheel Nut Torque: 110 Nm (11.5 kgf.m, 83 ft. lbs) Page 292 El - Un Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Page 3598 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Page 4463 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. Pre runner: INSTALL GREASE CAP Page 60 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Cruise Control System (w/ETCS-i) Neutral Safety Switch: Testing and Inspection Cruise Control System (w/ETCS-i) Park/Neutral Position Switch Circuit (A/T) CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECM. When this signal is input during the cruise control driving, the ECM cancels the cruise control. Wiring Diagram Step 1 Page 2027 Engine Bank Identification Page 1563 Engine Page 4190 Warranty Information NOTE OP Code 044184 and the above combination codes apply to all models with the EXCEPTION of Combo E for the MR2 Spyder model. APPLICABLE WARRANTY ^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 12 months or 20,000 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. Contents This bulletin is divided into the following sections: ^ Wheel Alignment and Tire Characteristics ^ Repair Procedure Flow Chart ^ Repair Procedure ^ Important Notice ^ Troubleshooting ^ Vehicle Pulling Caused by Wheel Alignment ^ Vehicle Pulling Caused by Tire Conicity Camber Adjustment Method Wheel Alignment & Tire Characteristics 1. Relationship Between Wheel Alignment and Vehicle Pulling to One Side Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM 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. Page 1463 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 4113 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 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. Testing and Inspection Air Bag Deactivation Indicator: Testing and Inspection PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH CONTINUITY HINT: Release the airbag activention 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. Check that continuity exists between terminals 5 and 6. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 3510 NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. e. Remove the generator with SST (A) and (B) from SST (C). f. Turn SST (B) and remove SST (A) and (B). g. Remove the pulley nut and pulley. 6. REMOVE RECTIFIER END FRAME a. Remove the 4 nuts. b. Using SST, remove the rectifier end frame. SST 09286-46011 c. Using snap ring pliers, remove the generator washer from the rectifier end frame. 7. REMOVE ROTOR FROM DRIVE END FRAME REASSEMBLY 1. INSTALL ROTOR TO DRIVE END FRAME a. Place the rectifier end frame on the pulley. b. Install the rotor to the rectifier end frame. 2. INSTALL RECTIFIER END FRAME a. Place the generator washer on the rotor. Page 3534 Neutral Safety Switch: Testing and Inspection Cruise Control System (w/o ETCS-i) Park/Neutral Position Switch Circuit (A/T) CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during the cruise control driving, the ECU cancels the cruise control. Wiring Diagram Step 1 Page 3064 5. DISCONNECT BRAKE LINE AND PARKING BRAKE CABLE a. Using SST, disconnect the brake line from the wheel cylinder . SST 09751-36011 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) b. 2WD: Remove the 2 bolts and disconnect the parking brake cable. Torque: 9.3 Nm (95 kgf-cm, 82 inch lbs.) 6. REMOVE REAR AXLE SHAFT ASSEMBLY a. Remove the 4 backing plate mounting nuts. Torque: 68 Nm (700 kgf-cm, 50 ft. lbs.) b. Pull out the rear axle shaft assembly from the rear axle housing. NOTICE: Be careful not to damage the oil seal. 7. 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 remove the serration bolts from the backing plate using a hammer. NOTICE: Do not reuse the nuts previously removed from the vehicle. b. Grind the retainer and sensor rotor surfaces using a grinder, then pry them out with a chisel and hammer. 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 Page 3813 Relay Box: Connector Views J/B No.1 - Lower Finish Panel Page 4457 3. 4WD: DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 5. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) c. Support the brake caliper securely. 6. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) Page 4408 Control Arm: Service and Repair Upper REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE SHOCK ABSORBER WITH COIL SPRING 2. w/ ABS: DISCONNECT ABS SPEED SENSOR WIRE HARNESS CLAMP Remove the 2 bolts and ABS speed sensor wire harness clamps from the steering knuckle and upper suspension arm. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 3. DISCONNECT UPPER BALL JOINT a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the hole for the cotter pin are not aligned, tighten the nut further up to 60°. Page 4122 J/B No.1 - Lower Finish Panel Page 3829 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. Page 1248 14. INSTALL FAN BRACKET a. Install the fan bracket with the bolt and nut b. Install the PS pump adjusting strut with the nut. 15. INSTALL NO.2 TIMING BELT COVER a. Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. 1. Using a screwdriver and gasket scraper, remove all the old gasket material. 2. Thoroughly clean all components to remove all the loose material. 3. Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. b. Install the timing belt cover with the 6 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c. Connect the 4 high-tension cord clamps and camshaft position sensor connector to the timing belt cover. 16. INSTALL OIL DIPSTICK AND GUIDE a. Install a new O-ring to the dipstick guide. b. Apply soapy water to the O-ring. c. Install the oil dipstick and guide to the cylinder block. d. Install the bolt to the generator bracket. Torque: 8 Nm (80 kgf-cm, 71 inch lbs.) 17. INSTALL A/C COMPRESSOR BRACKET Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.) 18. TEMPORARILY INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS 19. INSTALL NO.2 FAN SHROUD 20. INSTALL AND ADJUST DRIVE BELT FOR GENERATOR 21. TIGHTEN FAN WITH FLUID COUPLING AND FAN PULLEYS Torque: 5.4 Nm (54 kgf-cm, 48 inch lbs.) 22. CONNECT A/C COMPRESSOR TO ENGINE a. Install the A/C compressor with the 4 bolts. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) b. Install the drive belt. c. Connect the A/C compressor connector. 23. CONNECT PS PUMP TO ENGINE a. Temporarily install the PS pump with the bolt and nut. b. Install the drive belt. c. Tighten the bolt and nut. Torque: 43 Nm (440 kgf-cm, 31 ft. lbs.) d. Install the PS pressure tube clamp with the bolt. e. Connect the 2 PS air hoses to the air intake chamber and resonator. 24. CONNECT UPPER RADIATOR HOSE 25. FILL ENGINE WITH COOLANT 26. START ENGINE CHECK FOR LEAKS 27. INSTALL ENGINE UNDER COVER 28. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. Page 2104 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 4076 Relay Box: Electrical Diagrams J/B No.1 Inner Circuit Page 4717 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 squib connector. NOTE: 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, side airbag assembly, airbag sensor assembly, front airbag sensor side airbag sensor assembly or door side 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 992 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Page 2974 ^ 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 3659 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 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 4116 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 Page 2482 Fuel Pressure Regulator Part 2 Specifications Brake Rotor/Disc: Specifications Disc thickness STD ..................................................................................................................................................... ............................................ 22.0 mm (0.866 inch) Minimum .............................................................. ........................................................................................................................... 20.0 mm (0.787 inch) Disc runout Maximum ............................................................................................................................................. .......................................... 0.07 mm (0.0028 inch) Front disc brake caliper x Steering knuckle ..................................................................................................................... 123 Nm (1,250 kgf-cm, 90 ft. lbs.) Page 2499 Circuit Opening Relay Page 1454 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 2109 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. Locations Fuse: Locations R/B No.2 - Engine Compartment Left Locations Electronic Brake Control Module: Locations Engine Compartment Capacity Specifications Fluid - A/T: Capacity Specifications Automatic transmission fluid A340E Dry fill ......................................................................................... ......................................................................................... 7.2 L (7.6 US qts, 6.3 Imp. qts) Drain and refill ...................................................................................................................................................... ............... 1.6 L (1.7 US qts, 1.4 Imp. qts) A340F Dry fill ..................................................................... ......................................................................................................... 10.1 L (10.7 US qts, 8.9 Imp. qts) Drain and refill .............................................................................................................................. ....................................... 2.0 L (2.1 US qts, 1.8 Imp. qts) Page 1631 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 2313 Page 4520 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Page 3741 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 2009 Knock Sensor Part 2 Page 949 Refrigerant Oil: Fluid Type Specifications Air Conditioning - Lubricant Air Conditioning - Lubricant ITEM CLASSIFICATION Compressor oil ND-OIL 8 or equivalent Page 3487 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 604 Engine Page 1451 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 1045 Relay Box: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 79 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 310 Master switch (4 door): INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT FRONT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Page 857 HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). c. Install a new adjusting shim. 1. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2. Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Page 4752 Air Bag Deactivation Switch: Testing and Inspection PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH CONTINUITY HINT: Release the airbag activention 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. Check that continuity exists between terminals 5 and 6. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 3974 J/B No.3 Inner Circuit Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 1037 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 2585 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 4603 - Blower speed switch HI - Temperature control lever Max. COOL c. Connect the connector to amplifier and inspect wire harness side connector from the back side as shown in the chart. Test conditions: Running engine at idle speed - Blower speed switch HI - A/C switch ON - Temperature control lever Max. COOL Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB REMOVE SPEED SENSOR a. Disconnect the speed sensor connector. b. Remove the 2 (4WD and pre runner) or 4 (2WD (except pre runner)) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm, steering knuckle: 8.0 Nm (82 kgf-cm, 71 inch lbs.) Side rail: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. ^ The sensor is installed flat against the knuckle when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation Is in the reverse order of removal. NOTICE: After Installation, check the speed sensor signal. Page 1194 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: API grade SL Energy-Conserving or ILSAC multi-grade engine oil. 2. CHECK ENGINE OIL LEVEL After warming up the engine and then 5 minutes after the engine stop, the oil level should be between the low level and full level marks on the dipstick. If low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 3. REMOVE OIL PRESSURE SWITCH Using SST, remove the oil pressure switch. SST 09268-06021 4. INSTALL OIL PRESSURE GAUGE 5. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 6. CHECK OIL PRESSURE Oil pressure 7. REMOVE OIL PRESSURE GAUGE Page 340 Anti-lock Brake System Page 4678 Refrigerant Pressure Sensor / Switch: Testing and Inspection ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT PARTS 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Disconnect the pressure switch connector. b. Using an ohmmeter, check that there is continuity between the terminals. c. When refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Locations Fuse Block: Locations R/B No.2 - Engine Compartment Left Page 2805 ^ 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 3767 J/B No.3 - Behind The Instrument Panel Center Page 1076 J/B No.3 Inner Circuit Page 3127 Wiring Diagram Diagrams Wheel Hub: Diagrams Part 1 Of 2 Page 3079 Part 2 Of 2 REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 2365 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 810 Fuel Pressure: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See step 4). f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay, fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. 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 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 1069 Relay Box: Connector Views J/B No.1 - Lower Finish Panel Page 856 Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. Page 4729 Air Bag Harness: Testing and Inspection Replacement Requirements REPLACEMENT In the following cases, replace the wire harness or connector. - If any part of the SRS wire harness or any connector has been found to be faulty in troubleshooting. - If any part of the SRS wire harness or any connector has been found to be faulty during checking items. NOTE: If the wire harness used in the SRS is damaged, replace the whole wire harness assembly. Page 1332 Automatic Transmission Page 1125 Vehicle Lift And Support Locations Part 2 Page 2130 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. Locations ABS - Di Page 4091 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Air-Fuel Ratio (A/F) Sensor Oxygen Sensor: Testing and Inspection Air-Fuel Ratio (A/F) Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT If the resistance is not as specified, replace the sensor Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 3691 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Page 1446 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 3732 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 1771 If operation is as not specified, replace the fuel pump and/or set plate. b. Connect the fuel pump connector. c. Install the floor service hole cover with the 3 screws. d. Connect the LH rear seat cushion. Page 2590 Engine Page 1643 CHART 11 Page 550 CHART 21 Page 4115 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 2659 Ignition Coil: Testing and Inspection 1. INSPECT IGNITOR AND SPARK TEST Check that the spark occurs. 1. Disconnect high-tension cords from spark plug. 2. Remove the spark plug. 3. Install the spark plug to each high-tension cord. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent excess fuel being injected from the injectors during this test, do not crank the engine for more 5 - 10 seconds at a time. If the spark does not occur, do the test as shown. 6. Using a 16 mm plug wrench, install the spark plugs. Torque: 18 N.m (195 kgf.cm, 15 ft.lbf) 7. Reinstall the ignition coil with ignitor. 2. INSPECT IGNITION COIL a. Remove the air cleaner hose. b. Disconnect the high-tension cords and ignition coil connectors from the ignition coils. Specifications Engine Oil Pressure: Specifications Oil pressure Normal operating temperature at idle speed ...................................................................................................................................................... 29 kPa (0.3 kgf/cm2, 4.3 psi) or more at 3,000 rpm ......................................................................................................................................... 245 - 520 kPa (2.5 - 5.3 kgf/cm2, 36 - 75 psi) Page 1705 Engine Page 1053 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Service and Repair 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. Locations Page 1100 Part 2 Of 2 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 1249 29. RECHECK ENGINE COOLANT LEVEL Page 1976 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. Vehicle Lift and Support Locations (Double Cab) Vehicle Lifting: Locations Vehicle Lift and Support Locations (Double Cab) Vehicle Lift and Support Locations Locations R/B No.2 - Engine Compartment Left Page 1386 Thermostat: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT LOWER RADIATOR HOSE 3. REMOVE THERMOSTAT a. Remove the 3 nuts, water inlet and thermostat with gasket from the water pump. b. Remove the gasket from the thermostat. INSPECTION INSPECT THERMOSTAT HINT: Thermostat is numbered according to the valve opening temperature. a. Immerse the thermostat in water and gradually heat the water. Page 669 Air Bag Deactivation Switch: Testing and Inspection PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH CONTINUITY HINT: Release the airbag activention 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. Check that continuity exists between terminals 5 and 6. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 4651 Heater Unit (Part 2) REMOVAL 1. REMOVE COOLING UNIT 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 3. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES a. Using pliers, grip the claw of the hose clip and slide the clip along the hose Page 1850 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 to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 205 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 1066 "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 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. "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 2612 b. Install the throttle body with the 2 bolts and 2 nuts. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) c. Connect the throttle position sensor connector. d. Connect the throttle control motor connector e. Connect the accelerator pedal position sensor connector. f. Connect the air hose. g. Connect the 2 water bypass hoses. 2. CONNECT ACCELERATOR CABLE TO THROTTLE BODY 3. INSTALL AIR CLEANER HOSE 4. FILL WITH ENGINE COOLANT 5. START ENGINE AND CHECK FOR COOLANT LEAKS Page 636 Engine Specifications Brake Hose/Line: Specifications Brake line union nut ............................................................................................................................................................. 15 Nm (155 kgf-cm, 11 ft. lbs.) Page 2940 El - Un Page 1938 ^ 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. Testing and Inspection Control Module: Testing and Inspection Terminals Of ECM/Pinouts Locations Ignition Switch: Locations Ignition Switch And Key Unlock Warning Switch Page 125 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 4109 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 2191 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 405 Body Control System Page 3076 Part 2 Of 2 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 2815 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 - 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 2615 a. Using a soft brush and carburetor cleaner, clean the cast parts. b. Using compressed air, clean all the passages and apertures. NOTE: To prevent deterioration, do not clean the throttle position sensor and IAC valve. 2. INSPECT THROTTLE VALVE a. Apply vacuum to the throttle opener. b. Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. Throttle valve fully closed angle: 10° 3. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Insert a feeler gauge between the throttle stop screw and stop lever. c. Using an ohmmeter, measure the resistance between each terminal. Page 492 Engine Coolant Temperature (ECT) Sensor Page 3864 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Page 3541 Page 1942 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. Locations Evaporative Vapor Pressure Sensor: Locations Bu - VSV (Double Cab) Page 3650 2. Disconnect connector "B" and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector "A" and terminal 1 of connector "B 1" -> Continuity Between terminal 1 of connector "B2" and terminal 1 of connector "C" -> No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". b. Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5 V output terminal, terminal 1 of connector "B", and terminal 1 of connector "C", in that order. If the results are: 5 V: Between Terminal 1 of connector "A" and Body Ground 5 V: Between Terminal 1 of connector "B" and Body Ground 0 V: Between Terminal 1 of connector "C" and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of "B" and terminal 1 of "C". 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a "continuity check with ground". Check the continuity with ground. Page 3578 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1366 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. Locations Electronic Throttle Actuator: Locations Id - Wi Page 3081 7. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using 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 Installation is in the reverse order of removal. HINT: After installation, bleed the brake system, check the front wheel alignment and ABS speed sensor signal. Page 1611 Engine Description and Operation Malfunction Lamp / Indicator: 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 operating 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. Locations Starter Relay: Locations R/B No.2 - Engine Compartment Left Page 662 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT 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 APPROX. 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 Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. Page 245 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3673 Engine Compartment Instrument Panel Locations Page 4444 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 REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder, as shown in the illustration to remove the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. INSTALLATION Installation is in the reverse order of removal. Page 912 Coolant: Service and Repair REPLACEMENT 1. 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. Loosen the drain plugs, and drain the engine coolant. c. Close the drain plugs. 2. REFILL WITH ENGINE COOLANT a. Slowly fill the system with engine coolant. 1. Use of improper coolants may damage engine cooling system. 2. Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the manufacturer's directions. 3. 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%. DO NOT FURTHER DILUTE PRE-MIXED MANUFACTURER APPROVED ETHYLENE GLYCOL BASED COOLANT IF USED. NOTICE: Do not use an alcohol type engine coolant. - The engine coolant should be mixed with demineralized water or distilled water. Capacity b. Reinstall the radiator cap. c. Start the engine, and bleed the cooling system. d. If necessary, refill engine coolant into the reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Locations Crankshaft Position Sensor: Locations A/C - Ho Page 61 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 3870 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 297 El - Un Page 1946 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 1591 Engine Page 3590 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 4814 Instrument Panel Page 3810 "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 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. "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 4358 Page 1286 d. Reconnect and install the high-tension cords as shown in the illustration. Engine Controls/Electrical - Intermittent Hard Start Technical Service Bulletin # EG042-04 Date: 040920 Engine Controls/Electrical - Intermittent Hard Start ENGINE EG042-04 Title: INTERMITTENT EXTENDED OR "HARD" CRANKING Models: '03 - '04 Tacoma (V6) September 20, 2004 Introduction Some 2003 - 2004 model year Tacoma (V6) vehicles may experience an intermittent extended or "hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition. Applicable Vehicles ^ 2003 - 2004 model year Tacoma vehicles equipped with 5VZ-FE ("6) engines. 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. Location Page 3283 Anti-lock Brake System Page 1263 If operation is as not specified, replace the fuel pump and/or set plate. b. Connect the fuel pump connector. c. Install the floor service hole cover with the 3 screws. d. Connect the LH rear seat cushion. 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 Page 4581 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. 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 07112-76060 Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB REMOVE SPEED SENSOR a. Disconnect the speed sensor connector. b. Remove the 2 (4WD and pre runner) or 4 (2WD (except pre runner)) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm, steering knuckle: 8.0 Nm (82 kgf-cm, 71 inch lbs.) Side rail: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. ^ The sensor is installed flat against the knuckle when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation Is in the reverse order of removal. NOTICE: After Installation, check the speed sensor signal. Page 4321 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 degrees. HINT: Make a note of the steering angle. 2. ADJUST STEERING ANGLE a. Lift up the vehicle. NOTICE: The adjustment method for steering angle is different depending on the models. Check whether it is type A or B. b. Draw a line on the RH and LH tie rod and rack ends where it can easily be seen. c. 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. d. Remove the RH and LH boot clips from the rack boots. e. Loosen the RH and LH lock nuts. f. Turn the RH and LH rack end by the same amount (but in different directions) according to the steering angle. 1 turn 360 degrees. of rack end (1.5 mm (0.059 inch) horizontal movement) = 12 degree. of steering angle g. Tighten the RH and LH lock nuts by the specified torque. 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). h. Install the RH and LH boot clips. Page 2916 Step 5 INSPECTION PROCEDURE Page 4204 Tire size: P265/70R16 111S ............................................................................................................................................. 1°53' ± 45' (1.88° ± 0.75°) Tire size: P265/70R16 111T .............................................................................................................................................. 1°51'± 45' (1.85° ± 0.75°) VZN195L-PRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 2°31' ± 45' (2.53° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 2°35' ± 45' (2.59° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 2°33' ± 45' (2.56° ± 0.75°) Off-road package ................................................................................................................................. .................................... 2°39' ± 45' (2.66° ± 0.75°) RZN196L-CRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................................................................. 1°43' ± 45' (1.72° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................. 1°44' ± 45' (1.73° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................. 1°43' ± 45' (1.71° ± 0.75°) Off-road package ................................................................................................... ............................................................. 1°56' ± 45' (1.94° ± 0.75°) Heavy-duty leaf spring Tire size: P225/75R15 102S ............................................................................................................................................. 1°52' ± 45' (1.86° ± 0.75°) Tire size: P265/70R16 111S ............................................................................................................................................ 1 °52' ± 45' (1.87° ± 0.75°) Tire size: P265/70R16 111T ............................................................................................................................................ 1°51' ± 45' (1.85 ° ± 0.75°) RZN196L-PRPDKAB Normal Tire size: P225/75R15 102S .......................................................................................................................................... 2°34' ± 45' (2.58° ± 0.75°) Tire size: P265/70R16 111S .......................................................................................................................................... 2°35' ± 45' (2.59° ± 0.75°) Tire size: P265/70R16 111T .......................................................................................................................................... 2°33' ± 45' (2.56° ± 0.75°) Off-road package ........................................................................................................ ........................................................ 2°45'± 45' (2.75° ± 0.75°) Steering axis inclination Right - left error: 30' (0.5 or less) RZN161L models ............................................................................................................................................................. 10°30' ± 45' (10.5° ± 0.75°) VZN170L-CRMDKAB Except off-road package ................................................................................................................................................. 10°30' ± 45' (10.5° ± 0.75°) Off-road package ............................................................................................................................................................. 10°42' ± 45' (10.7° ± 0.75°) VZN170L-CRPDKAB Except off-road package ................................................................................................................................................. 10°30' ± 45' (10.5° ± 0.75°) Off-road package .......................................................................................................................................................... 10° 36' ± 45' (110.6° ± 0.75°) VZN170L-PRPDKAB ................................................................................................................................................... 11 °00' ± 45' (11.0° ± 0.75°) RZN171L-CRMDKAB Except off-road package ................................................................................................................................................. 10°24' ± 45' (10.4° ± 0.75°) Off-road package ............................................................................................................................................................. 10°49' ± 45' (10.7° ± 0.75°) RZN171L-CRPDKAB .................................................................................................................................................. 10°30' ± 45' (110.5° ± 0.75°) RZNI91L-TRPDKAB ..................................................................................................................................................... 10°24' ± 45' (10.4° ± 0.75°) VZN195L-CRPDKAB Except off-road package .................................................................................................................................................. 10°30'± 45' (10.5° ± 0.75°) Off-road package ............................................................................................................................................................. 10°36' ± 45' (10.6° ± 0.75°) VZN195L-PRPDKAB .................................................................................................................................................... 11°00' ± 45' (11.0° ± 0.75°) VZN196L-CRPDKAB Except off-road package ................................................................................................................................................. 10°24' ± 45' (10.4° ± 0.75°) Off-road package ............................................................................................................................................................. 10°36' ± 45' (10.6° ± 0.75°) VZN196L-PRPDKAB Normal ................................................................................................................................................. ........................... 10°54' ± 45' (10.9° ± 0.75°) Off-road package ................................................................................................................................. .................................. 11°12' ± 45' (11.2° ± 0.75°) ^ Toe - in (Total) .......................................................................................................................... Rack end length difference: 1.5 mm (0.059 inch) or less RZN161L-TRMDKAB Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.3 ± 2 mm, 0.05 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ............................................................................................................... 0°07' ± 12' (0.11° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) RZN161L-TRPDKAB Tire size: P225/75R125 102S ............................................................................................. 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ................................................................................................................. 0°07'± 12' (0.12° ± 0.2° 1.5 ± 2 mm, 0.06 ± 0.08 inch) VZN170L-CRMDKAB Except off-road package Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/75R16 111S, P265/70R16 111T ................................................................................................................ 0°07'± 12' (0.12° ± 0.2°, 1.5 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ................................................................................................................ 0°02' ± 12' (0.03° ± 0.2°, 0.4 ± 2 mm, 0.02 ± 0.08 inch) VZN170L-CRPDKAB Except off-road package Locations Wheel Speed Sensor: Locations A/C - Ho Page 3400 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 1943 ^ 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 490 Engine Page 2584 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 1481 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 4471 Vehicle Lifting: Service and Repair Vehicle Lift And Support Locations Part 1 Page 1606 Engine The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 898 Hose/Line HVAC: Testing and Inspection REFRIGERANT LINE ON-VEHICLE INSPECTION 1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Locations Locations Crankshaft Position Sensor: Locations A/C - Ho Page 2279 Oxygen Sensor: 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 993 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 2649 Engine Diagrams Steering Gear: Diagrams Part 1 of 3 Page 3901 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 804 Camber: -0°10' (-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: -(Shorter) 2.9 Rear cam: -(Shorter) 2.7 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) 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 HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less Page 4459 Wheel Hub: Service and Repair Disassembly and Assembly Part 1 Of 2 Locations El - Un Page 73 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Locations El - Un Page 3486 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. Diagrams Cooling Unit Page 1779 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. A/C switch is OFF. 2. CONNECT HAND-HELD TESTER OR OBD II SCAN TOOL a. Connect the hand-held tester or OBD II scan tool to the DLC3. b. Please refer to the hand-held tester or OBD II scan tool operator's manual for further details. 3. INSPECT IDLE SPEED a. Race the engine speed at 1,000 rpm for approximately 5 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT HAND-HELD TESTER OR OBD II SCAN TOOL Page 2052 CHART 15 Locations Automatic Transmission Page 3250 Bu - VSV (Except Double Cab) Page 4458 7. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using 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 Installation is in the reverse order of removal. HINT: After installation, bleed the brake system, check the front wheel alignment and ABS speed sensor signal. Page 1847 Automatic Transmission Page 260 Air Bag Control Module: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor assembly and judges whether the SRS must be activated or not and diagnosis system malfunctions. Page 3895 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM 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. Locations Page 3096 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 2306 Page 3734 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 4659 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Service and Repair Towing Information: Service and Repair Dinghy Towing Your vehicle is not designed to be towed (with four wheels on the ground) behind a motorhome. Caution: Do not tow your vehicle with four wheels on the ground. This may cause serious damage to your vehicle. Page 2169 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 3102 1. 3-joint type: SEPARATE PROPELLER SHAFT AND INTERMEDIATE SHAFT a. Place matchmarks on the flanges. b. Remove the 4 nuts, bolts and washers. c. Separate the propeller shaft and intermediate shaft. 2. 3-joint type: REMOVE FLANGE FROM INTERMEDIATE SHAFT a. Using a chisel and hammer, loosen the staked part of the nut. 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 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) e. Remove the spacer. 3. 3-joint type: REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT 4. REMOVE SLEEVE YOKE FROM PROPELLER SHAFT a. Place matchmarks on the sleeve yoke and shaft. b. Pull out the sleeve yoke from the shaft. c. Remove the dust cover from the shaft. INSPECTION NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Page 1553 Engine Page 793 NOTE Adjusting value for the set bolts is 6' - 30' (0.1° 0.5°). When making an adjustment of more than 45' replace the upper and lower steering knuckle set bolts with the adjusting bolts. If the camber is NOT within the specification, use the table shown to estimate how much additional camber adjustment will be required, and select the appropriate camber adjusting bolt. I. Follow steps 4A through 4H again. Between steps 4B and 4C exchange one or two selected bolts. HINT When exchanging the two bolts, exchange one bolt at a time. If Vehicle Pull Is Eliminated: Repair Is Now Complete. Page 147 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 Relay Box: Locations R/B No.2 - Engine Compartment Left Page 2490 Fuel Pressure: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand- held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See step 4). f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay, fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. 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 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 1585 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 548 CHART 20 Page 2502 Fuel Pump Relay: Testing and Inspection EFI Main Relay INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. Page 2397 Engine Page 2408 Engine Page 2687 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 1731 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Page 3926 J/B No.1 Part-3 Interior Panel Fuse Details Page 3911 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 3426 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 2611 2. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 3. REMOVE AIR CLEANER HOSE 4. 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 air hose. e. Disconnect the 2 water bypass hoses. f. Remove the 2 bolts, 2 nuts, throttle body and gasket. INSTALLATION 1. INSTALL THROTTLE BODY a. Place a new gasket on the air intake chamber facing the protrusion upward. Page 1060 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Page 318 Power Seat Switch: Testing and Inspection 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. b. Inspect the connector on the wire harness side. If circuit is not as specified, inspect the circuits connected to other parts. Page 3971 J/B No.3 - Behind The Instrument Panel Center Page 2314 CHART 28 Page 3820 J/B No.3 Inner Circuit Page 2217 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 2418 Engine Page 872 c. Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d. Install the timing belt to the No.2 idler pulley. e. Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f. Install the timing belt to the water pump pulley. g. Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h. Install the timing belt to the No.1 idler pulley. 8. SET TIMING BELT TENSIONER a. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 200 - 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 tensioner. 9. INSTALL TIMING BELT TENSIONER a. Temporarily install the tensioner with the 2 bolts. b. Alternately tighten the 2 bolts. Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.) c. Remove the 1.27 mm hexagon wrench from the tensioner. 10. CHECK VALVE TIMING a. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. Page 3036 Fluid - Differential: Fluid Type Specifications Differential oil Oil grade ....................................................................................................................... ................................................................ Hypoid gear oil API GL-5 Viscosity Above -18° C (0° F) .... .............................................................................................................................................................. ................. SAE 90 Viscosity Below -18° C (0° F) ............................................................................................................................................................ SAE 80w or 80w-90w Page 4547 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Locations Throttle Position Sensor: Locations Id - Wi Page 3622 J/B No.1 - Lower Finish Panel Locations Daytime Running Lamp Relay: Locations Instrument Panel w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 55 Engine Compartment Instrument Panel Locations Page 4608 Control Assembly: Service and Repair Disassembly and Reassembly HEATER CONTROL ASSEMBLY DISASSEMBLY 1. REMOVE A/C SWITCH KNOB AND REC SWITCH KNOB Using a small screwdriver, pry out the 2 knobs. HINT: Tape the small screwdriver tip before use. 2. REMOVE A/C AMPLIFIER a. Remove the 5 screws. b. Remove the A/C control panel case and amplifier. 3. REMOVE BULB Using a screwdriver, turn the bulb to the left and pull out the bulb. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 2555 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 3402 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 3. INSTALL MASTER CYLINDER 4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM 5. CHECK FOR FLUID LEAKAGE 6. CHECK AND ADJUST BRAKE PEDAL 7. DO OPERATIONAL CHECK Page 2561 Engine Page 2272 Engine Bank Identification Page 1654 CHART 23 Locations Camshaft Position Sensor: Locations A/C - Ho Page 278 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Locations Throttle Position Sensor: Locations Id - Wi Page 1704 Engine Page 702 El - Un Page 3576 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 1009 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 Page 2008 Knock Sensor Part 1 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 4171 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Page 4088 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. 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 the wire routing is shown in square brackets [ ]. 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 3103 1. INSPECT PROPELLER SHAFT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT a. Inspect the shafts for wear or damage. b. Using a dial indicator, check the runout of the shafts. Maximum runout: 0.8 mm (0.031 inch) If the shaft runout exceeds the maximum, replace the shaft. 2. INSPECT SPIDER BEARING a. Inspect the spider bearings for wear or damage. b. Using a dial indicator, check the spider bearing axial play by turning the yoke while holding the shaft tightly Maximum bearing axial play: 0.05 mm (0.0020 inch) If the spider bearing axial play exceeds the maximum, replace the spider bearing. 3. 3-joint type: 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. w/ Double cardan joint 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. REASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Page 930 Engine Oil: Fluid Type Specifications Grade ................................................................................................................................ API SH, Energy-Conserving II or ILSAC multigrade engine oil. Viscosity ......................................................... ............................................................................................................................................................ 5W-30 Page 199 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 2383 Canister Purge Solenoid: Testing and Inspection 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 Ohm at 20 °C (68 °F) If there is no continuity, replace the VSV. b. Inspect 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 port E to port F. Page 3634 Glossary Of Terms And Symbols Part 1 Page 3101 Drive/Propeller Shaft: Service and Repair Disassembly and Reassembly DISASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Page 4255 NOTICE: When using a vise, do not overtighten it. 1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID 2. INSTALL STRAIGHT PINS Using a plastic hammer, tap in 2 new straight pins to the front housing. NOTICE: Be careful not to damage the pins. 3. INSTALL VANE PUMP SHAFT 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 rotor with the inscribed mark facing outward. b. Install a new snap ring to the vane pump shaft. 6. INSTALL VANE PLATES Install the 10 plates with the round end facing outward. 7. INSTALL GASKET Page 4056 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Page 1546 Engine 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 Locations Control Unit: Locations Instrument Panel Page 3606 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 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 Relay Box: Locations R/B No.2 - Engine Compartment Left Locations Air Flow Meter/Sensor: Locations Engine Page 4445 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber ASSY Rear LH (W/O Reas) Replacement FRONT SHOCK ABSORBER REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 917 Fluid - A/T: Fluid Type Specifications Automatic transmission fluid ................................................................................................................ ................................................................. ATF T-IV Page 3589 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART Page 1513 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 3884 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 244 Fuel Pump Relay: Testing and Inspection EFI Main Relay INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. Page 2842 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 4383 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 1032 J/B No.1 - Lower Finish Panel Details Page 153 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 2553 Engine Page 2573 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 3463 Neutral Safety Switch: Testing and Inspection Cruise Control System (w/o ETCS-i) Park/Neutral Position Switch Circuit (A/T) CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during the cruise control driving, the ECU cancels the cruise control. Wiring Diagram Step 1 Page 2333 Engine Page 2787 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 3761 "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 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. "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 4767 - When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. Deployment When Disposing of Steering Wheel Pad 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-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 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. Page 4192 if the steering wheel is held without exerting steering effort for 109 yards (100 m) when traveling at 62 mph (100 km/h), the vehicle may drift as much as 5 feet (1.5 m). ^ When vehicle pulling is due to conicity, the amount of drift can be reduced and the direction of drift can be changed by changing the location of the tire or reversing the tire when installing it on the wheel. Repair Procedure Flow Chart Repair Procedure IMPORTANT NOTICE Before repairing vehicle pulling to one side, it is necessary to clearly identify the cause of the pulling condition. Frequently, the cause of the vehicle pulling to one side is diagnosed as wheel alignment. However, the actual cause may be lateral force generated by the tires. Performing wheel alignment when tire force is the cause could result in the wheel alignment being set at a value outside of specifications. This would then cause other problems such as uneven tire wear; etc. 1. Troubleshooting First determine whether vehicle pulling to one side is caused by a wheel alignment problem or tire characteristics, then decide which repairs to make. A. Perform the following checks and correct as necessary. (1) Check tires for size, wear and for proper inflation pressure. (2) Check whether the vehicle is noticeably tilted backward/forward or left/right. NOTE Tilting of the vehicle produces a left-right difference in the camber and caster and can cause vehicle pulling to one side. (3) Check brakes for dragging. B. Confirm problem symptoms. Page 1973 ^ 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 2639 Engine Page 3470 Engine 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 2871 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 1488 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 1940 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. 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 temperature sender gauge. Locations Id - Wi Page 3636 Fuse Block: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 522 Oxygen Sensor: 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 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 1304 SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size by following the Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T .......................................................................................................................................................... ........................ Thickness of used shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Page 2036 ^ 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 1110 6. 4WD: INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. Pre runner: INSTALL GREASE CAP Page 685 a. Install the front airbag sensor with the 2 bolts and 2 nuts with the arrows on the sensors facing toward the front of the vehicle. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) 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 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. 2. INSTALL BATTERY a. Install the battery carrier and battery. b. Install the battery clamp with the bolt. Page 1445 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 1492 ^ 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 Specifications Idle Speed: Specifications Idle speed ............................................................................................................................................ ............................................................. 700 ± 50 rpm Page 4058 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 3618 J/B No.1 Part-3 Interior Panel Fuse Details Page 2868 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 3272 Using SST, disconnect the 5 brake lines from the ABS actuator. SST 9023-00100 Torque, 15 Nm (155 kgf-cm, 11 ft. lbs.) 3. REMOVE ABS ACTUATOR ASSEMBLY Remove the bolt, 2 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.) 4. REMOVE ABS ACTUATOR Remove the 4 nuts and the ABS actuator. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. Page 4063 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Specifications Brake Bleeding: Specifications Fluid Type AE J1703 or FMVSS No.116 DOT3 Page 899 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 then 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 4742 2. REMOVE LOWER CENTER COVER 3. Double cab: DISCONNECT REAR HEATER DUCTS Remove the 2 bolts and disconnect the LH and RH rear heater ducts. 4. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the 3 connectors. NOTE: Remove the connector with the sensor assembly installed. b. Remove the bolt holding the No.1 brace to the floor. c. Using a torx wrench, remove the 3 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace 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 the 3 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) b. Remove the bolt holding the No.1 brace to the floor. c. Connect the 3 connectors. NOTE: Installation of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed to 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. Page 2574 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 2139 ^ 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 395 Refrigerant Pressure Sensor / Switch: Testing and Inspection ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT PARTS 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Disconnect the pressure switch connector. b. Using an ohmmeter, check that there is continuity between the terminals. c. When refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 1002 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Diagrams Throttle Body: Diagrams Throttle Body (w/o ETCS-i) Page 165 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 3975 J/B No.3 Inner Circuit Page 4820 Air Bag Control Module: Service and Repair 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 FRONT CONSOLE BOX Testing and Inspection 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 After connection, adjust the control cable. 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 4362 Locations Air Bag Deactivation Switch: Locations El - Un Page 2357 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Page 1685 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Page 3203 Step 5 INSPECTION PROCEDURE Locations Crankshaft Position Sensor: Locations A/C - Ho Page 2131 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 2105 ^ 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. Locations R/B No.2 - Engine Compartment Left Page 1926 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 1637 CHART 1 Page 2543 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) VALVE (w/o ETCS-i) ON-VEHICLE INSPECTION 1. INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF b. Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 c. After engine speed is kept at approx. 1,000 rpm for 5 seconds, check that it returns to the idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST from the DLC3. SST 09843-18040 2. INSPECT IAC VALVE RESISTANCE NOTE: "Cold" and "Hot" in the following 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). a. Disconnect the IAC valve connector. b. Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). If the resistance is not as specified, replace the IAC valve. c. Reconnect the IAC valve connector. Page 4007 3. Remove Left Front Tire. 4. Remove Front Fender Apron Seal. A. Remove the 12 clips and the front fender apron seal. 5. Remove Engine Under Cover. 6. Remove Engine No. 2 Wire (Access from Underside of Vehicle). A. Remove the bolt, and disconnect the ground strap. B. Disconnect the starter connector. C. Remove the nut, and disconnect the starter wire. Specifications Airbag Sensor Assembly Testing and Inspection Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kOhm per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Lower Ball Joint: Diagrams Lower FRONT LOWER BALL JOINT REPLACEMENT W/ RELATED COMPONENTS Page 2124 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 2642 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 803 a. Loosen the front and/or rear adjusting cam nuts. 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. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10' (0.17°) Caster: 1°40' (1.67°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Specifications Crankshaft: Specifications Thrust clearance STD ..................................................................................................................................................... .............. 0.020 - 0.220 mm (0.0008 - 0.0087 inch) Maximum ............................................................. .......................................................................................................................... 0.30 mm (0.0118 inch) Thrust washer thickness ........................................................................................................................................ 2.440 2.490 mm (0.0961 - 0.0980 inch) Main journal oil clearance STD No.3 ............................................................................................................................................................. 0.020 - 0.038 mm (0.0008 - 0.0015 inch) Others .......................................................................................................................................................... 0.024 - 0.042 mm (0.0009 - 0.0017 inch) U/S 0.25 ............................................................................................................................................................ 0.023 - 0.063 mm (0.0009 - 0.0025 inch) Maximum ............................................................................................................................................. .................................... 0.08 mm (0.0031 inch) Circle runout Maximum ............................................................................................................................................. .......................................... 0.06 mm (0.0024 inch) Crank pin diameter STD ..................................................................................................................................................... .......... 54.987 - 55.000 mm (2.1648 - 2.1654 inch) U/S 0.25 ........................................................................................................................................................ 54.745 - 54.755 mm (2.1553 - 2.1557 inch) Page 3776 J/B No.1 - Lower Finish Panel Details Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Page 3603 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 2069 CHART 28 Page 4168 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Page 87 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Specifications Tires: Specifications Cold tire inflation pressure P205/75R1597S Front .................................................................................................................................................... .......................... 200 kPa (2.0 kgf/cm2, 29 psi) Rear .......................................................................... ..................................................................................................... 200 kPa (2.0 kgf/cm2, 29 psi) P235/55R1696T Front .................................................................................................................................................... .......................... 200 kPa (2.0 kgf/cm2, 29 psi) Rear .......................................................................... ..................................................................................................... 220 kPa (2.2 kgf/cm2, 32 psi) P225/75R15102S Front .................................................................................................................................................... .......................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear .......................................................................... ..................................................................................................... 200 kPa (2.0 kgf/cm2, 29 psi) P265/70R16111S Front .................................................................................................................................................... .......................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear .......................................................................... ..................................................................................................... 180 kPa (1.8 kgf/cm2, 26 psi) P265/70R16111T Except double cab models Front .................................................................................................................................................... .................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear ................................................................................ ......................................................................................... 200 kPa (2.0 kgf/cm2, 29 psi) Double cab models Front .................................................................................................................................................... .................... 180 kPa (1.8 kgf/cm2, 26 psi) Rear ................................................................................ ........................................................................................ 180 kPa (1. 8 kgf/cm2, 26 psi) Page 513 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 2284 Testing and Inspection Control Module: Testing and Inspection Terminals Of ECM/Pinouts Page 140 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 3714 BN7 - BV1 (Except Double Cab) BU1 w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 4440 DISASSEMBLY REMOVE SUSPENSION SUPPORT AND COIL SPRING a. Using SST, compress the coil spring until there is a clearance on both ends. SST 09727-30021 NOTICE: ^ To avoid damage to SST, set SST arms to allow clearance to hold a 8-roll coil between them. ^ Do not compress the coil spring more than necessary. ^ Do not use an impact wrench. It will damage the SST. b. Remove suspension support center nut. Testing and Inspection 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 belt has chunks missing from the ribs, it should be replaced. b. Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Boroughs 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 1886 ^ 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 4528 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Locations Control Unit: Locations Instrument Panel Specifications Brake Pad: Specifications Front brake pad thickness STD ..................................................................................................................................................... ............................................ 11.5 mm (0.453 inch) Minimum .............................................................. ............................................................................................................................. 1.0 mm (0.039 inch) Page 4385 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 4197 NOTE Adjusting value for the set bolts is 6' - 30' (0.1° 0.5°). When making an adjustment of more than 45' replace the upper and lower steering knuckle set bolts with the adjusting bolts. If the camber is NOT within the specification, use the table shown to estimate how much additional camber adjustment will be required, and select the appropriate camber adjusting bolt. I. Follow steps 4A through 4H again. Between steps 4B and 4C exchange one or two selected bolts. HINT When exchanging the two bolts, exchange one bolt at a time. If Vehicle Pull Is Eliminated: Repair Is Now Complete. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 4614 Evaporator Case: Testing and Inspection On-Vehicle Inspection COOLING UNIT ON-VEHICLE INSPECTION INSPECT FOR LEAKAGE OF REFRIGERANT a. Remove the glove compartment parts. b. Remove the blower resistor. 1. Disconnect the connector. 2. Remove the 2 screws and blower resistor. c. Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints or check the evaporator. d. Install the blower resistor with the 2 screws. e. Install the glove compartment parts. Page 2640 Engine Page 4053 Step 1 Removal and Installation Wheel Hub: Service and Repair Removal and Installation Part 1 Of 2 Page 3249 Bu - VSV (Double Cab) Page 1826 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 629 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 3710 BN7 - BR2 (Double Cab) BN7 - BV1 (Except Double Cab) Page 2170 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 2332 Engine Page 446 Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminal and the switch body in the ON position (switch pin released : opened door). b. Check that no continuity exists between terminal and the switch body in the OFF position (switch pin pushed in : closed door). If operation is not as specified, replace the switch. Page 2292 CHART 8 CHART 9 Page 2229 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 1559 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3644 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Page 725 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 Crankshaft Gear/Sprocket: Specifications Crank pin diameter STD ..................................................................................................................................................... .......... 54.987 - 55.000 mm (2.1648 - 2.1654 inch) U/S 0.25 ........................................................................................................................................................ 54.745 - 54.755 mm (2.1553 - 2.1557 inch) Crank pin taper and out-of-round Maximum ............................................................................................................................................. .......................................... 0.02 mm (0.0008 inch) Page 3672 J/B No.1 - Lower Finish Panel Details Locations Air Flow Meter/Sensor: Locations Engine Locations Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left Page 1189 Assenmacher Specialty Tools 1-800-525-2943 Page 1046 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Locations Refrigerant Line Page 854 SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size by following the Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T .......................................................................................................................................................... ........................ Thickness of used shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Locations Power Door Lock Switch: Locations Bu - VSV (Double Cab) Specifications Fuel Pressure: Specifications Information not supplied by the manufacturer. Page 4155 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Page 4361 Page 3932 Engine Compartment Instrument Panel Locations Page 343 Wheel Speed Sensor: Diagrams Rear REAR SPEED SENSOR REPLACEMENT W/ RELATED COMPONENTS Page 4239 j. 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. k. Disconnect the SST. l. Connect the pressure feed tube. m. 5VZ-FE Engine: Install the air cleaner and 3 bolts. n. Bleed the power steering system. Electrical - SRS And HV Wiring Repairs Wiring Harness: All 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 1374 Engine Coolant Temperature (ECT) Sensor Page 4276 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM Page 3939 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 1655 Page 2045 CHART 5 CHART 6 Page 584 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Locations Air Flow Meter/Sensor: Locations Engine Page 3893 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Page 1545 Engine Page 512 Knock Sensor Part 2 Page 1693 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 4100 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 1011 "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 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. "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 4584 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. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) Page 1343 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. Page 1044 Glossary Of Terms And Symbols Part 2 Page 396 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE a. Disconnect the pressure switch connector. b. Remove the pressure switch and O-ring. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mounted 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 the switch. INSTALLATION Installation is in the reverse order of removal. Page 2884 Bu - VSV (Except Double Cab) Page 2676 Engine Page 3960 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Page 2047 CHART 8 CHART 9 Page 690 Seat Belt Buckle Switch: Testing and Inspection INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals on the switch side connector with the switch ON (belt unfastened). b. Check that no continuity exists between terminals on the switch side connector with the switch OFF (belt fastened). If operation is not as specified, replace the seat belt inner. Page 4012 K. Install the ground strap to the new position indicated by the arrow. Torque: 30 - 50 N.m (300 - 502 kgf.cm, 261 - 435 in.lbf) NOTE: Tighten the ground strap at an angle of 30° or less, as shown in the illustration, so that the oil cooler does not interfere with the wire. L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties. NOTE: The engine No. 2 wire harness (82122-35A60) includes 4 wire ties (90464-00551). Use two of them and keep other wire ties as spares. Page 3160 El - Un Specifications Fuel Pressure: Specifications Information not supplied by the manufacturer. Page 3443 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.). Locations Page 1633 Page 2317 Oxygen Sensor: Locations A/C - Ho Page 2132 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 3991 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. Page 3181 Bu - VSV (Double Cab) Page 4771 d. Install the SST. CAUTION: Place the disc wheel on the level ground. 1. Connect the connector of the 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. 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. Page 1207 Oil Cooler: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT OIL COOLER HOSES Disconnect the No.1 and No.2 oil cooler hoses. 3. REMOVE OIL COOLER Remove the bolt, relief valve, gaskets and oil cooler. Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.) HINT: At the time of installation, please refer to the following items. - Replace the O-ring with a new part. - Use a new gasket to the relief valve. INSPECTION INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. INSTALLATION Installation is in the reverse order of removal. Page 3713 BN7 - BR2 (Double Cab) Page 2210 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 3748 The suspected circuits or parts for each problem symptom are shown in the table. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Page 1243 - Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects, as shown in the illustrations, check these points: 1. Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation. 2. If the belt teeth are cracked or damaged, check to see if either camshaft is locked. 3. 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. 4. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. 5. If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation, 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. 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. Page 192 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 4406 4. DISCONNECT SHOCK ABSORBER a. Remove the shock absorber lower nut and washer. Torque: 135 Nm (1,400 kgf-cm, 101 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. b. With lowering the lower suspension arm, remove the bolt and disconnect the shock absorber. 5. DISCONNECT LOWER BALL JOINT a. Support the upper suspension arm and steering knuckle securely. b. Remove the cotter pin and nut from the lower ball joint. Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. Using SST, disconnect the lower ball joint from the lower suspension arm. SST 09628-62011 NOTICE: Be careful not to damage the lower ball joint. HINT: At the time of installation, face the cotter pin hole of the lower ball joint forward. 6. REMOVE LOWER SUSPENSION ARM a. Place matchmarks on the front and rear adjusting cams. b. Remove the nuts, adjusting cams, bolt and lower suspension arm. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Page 752 Automatic Transmission Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned on, battery positive voltage is applied to terminal IGSW of the ECM and the EFI main relay (Marking: EFI) control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI main relay. This signal causes current to flow to the coil, closing the contacts of the EFI, main relay and supplying power to terminals +B of the ECM. w/o ETCS: If the ignition switch is turned off, the ECM continues to switch on the EFI main relay for a maximum of 2 seconds for the initial setting of the IAC valve. Wiring Diagram Page 4369 Page 2854 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 1632 Locations R/B No.2 - Engine Compartment Left Page 967 J/B No.1 - Lower Finish Panel Details Page 3180 El - Un Page 3843 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Specifications Front Airbag Sensor Page 2668 Knock Sensor Part 1 Diagrams Compressor Clutch: Diagrams Compressor And Magnetic Clutch Page 1444 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 3547 5. INSPECT BRUSHES 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. 6. INSPECT BRUSH SPRINGS Check the brush spring load. Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load Specifications Airbag Sensor Assembly Page 1983 Terminals Of ECM/ Pinouts Part 2 Page 1188 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 1945 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 2140 Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Engine Control Module -- Go to Powertrain Management Diagrams. Page 4409 b. Using 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 UPPER SUSPENSION ARM Remove the nut, bolt, 2 washers and upper suspension arm. Torque: 115 Nm (1,200 kgf-cm, 87 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment. 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 1430 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. Locations Automatic Transmission 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 Page 4705 - There should be no interference between the instrument panel and front passenger airbag door, or the glove compartment door and front passenger airbag door. The clearance should be uniform all the way around when the new airbag assembly is installed on the instrument panel. CAUTION: Be sure to follow the correct procedure, for removal and installation of the front passenger airbag assembly. VEHICLE INVOLVED EN COLLISION AND AIRBAG IS DEPLOYED a. Do a diagnostic system check. * b. Do a visual check which includes the following items with the airbag assembly removed from the vehicle. - Check for deformation of the instrument panel, instrument panel reinforcement and glove compartment door. - Check for damage to the connector and wire harness. HINT: If the instrument panel or instrument panel reinforcement is deformed, never repair it. Always replace it with a new one. - There should be no interference between the instrument panel and front passenger airbag door, or the glove compartment and front passenger airbag door. The clearance should be uniform all the way around when the new airbag assembly is installed on the instrument panel. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACEMENT CAUTION: Be sure to follow the correct procedure, for replacement of the front passenger airbag assembly. STEERING WHEEL PAD AND SPIRAL CABLE a. Do a diagnostic system check. * 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 INSPECT SUPPLEMENTAL RESTRAINT SYSTEM a. Do a diagnostic system check. * Page 63 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 4813 Air Bag Control Module: Locations Airbag Sensor Assembly Page 3640 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 2296 CHART 14 Page 970 R/B No.2 Part-2 Engine Room Fuse Details J/B No.1 Part-1 Page 4252 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 front housing and vane pump shaft. 2. INSPECT VANE PUMP ROTOR AND VANE PLATES 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: 0.035 mm (0.0014 inch) Page 1925 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 1671 Oxygen Sensor: Service Precautions MAINTENANCE PRECAUTIONS Precautions when the handling oxygen sensors. 1. Do not allow oxygen sensor to drop or hit against an object. 2. Do not allow the sensor to come into contact with water. Page 2717 Shift Solenoid: Diagrams The shift solenoid identification and location in the valve body is contained in the valve body service and repair procedures and overhaul articles for most models. Page 978 Engine Compartment Instrument Panel Locations Page 802 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). INSPECTION HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. MEASURE VEHICLE HEIGHT Measuring points: A: Ground clearance of spindle center B: Ground clearance of front adjusting cam bolt center C: Ground clearance of rear axle shaft center D: Ground clearance of leaf spring front hanger pin bolt center 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-KINGPIN 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 Page 266 - When installing the airbag sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL REMOVED PARTS Page 3742 Customer Problem Analysis Check (Sample) Engine control system check sheet Symptom Confirmation and Diagnostic Trouble Code Check SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TACOMA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA TACOMA. Component Tests and General Diagnostics Air Bag Control Module: Component Tests and General Diagnostics Collision / Non-Collision Inspections 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION AND SRS IS NOT DEPLOYED Do a diagnostic system check. * 3. VEHICLES INVOLVED IN COLLISION AND SRS IS 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/Initial Inspection and Diagnostic Overview Replacement Requirements REPLACEMENT 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: Be sure to follow the correct procedure, for removal and installation of the airbag sensor assembly. Page 659 Engine Specifications Stabilizer Bar: Specifications Stabilizer bar link x Stabilizer bar ........................................................................................................................................ 69 Nm (700 kgf-cm, 51 ft. lbs.) Stabilizer bar link x Lower suspension arm ......................................................................................................................... 90 Nm (920 kgf-cm, 66 ft. lbs.) Stabilizer bar bracket x Frame .............................................................................................................................................. 25 Nm (260 kgf-cm, 19 ft. lbs.) Page 3656 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Locations Transmission Control System Relay: Locations Instrument Panel Locations Data Link Connector: Locations ABS - Di Page 4582 d. Remove the shims from the pressure palate. 2. REMOVE ROTOR a. Using SST, remove the snap ring. SST 95994-10020 NOTE: At the time of reassembly, please refer to the following item. 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 635 Engine Page 4372 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 3762 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. Capacity Specifications Engine Oil: Capacity Specifications Capacity 2WD Drain and refill W/ Oil filter change .............................................................................................................................................................. 5.9 L (6.2 US qts, 5.2 Imp. qts) W/o oil filter change ............................................................................................................................................................. 5.1 L (5.4 US qts, 4.5 Imp. qts) Dry fill ................................................................................................. ................................................................................. 6.3 L (6.7 US qts, 5.5 Imp. qts) 4WD Drain and refill W/ oil filter change ....................................................................................................................... ........................................ 5.2 L (5.5 US qts, 4.6 Imp. qts) W/o Oil filter change ............................................................................................................................................................ 4.9 L (5.2 US qts, 4.3 Imp. qts) Dry fill ................................................................................................. ................................................................................. 5.9 L (6.2 US qts, 5.2 Imp. qts) Page 4149 HINT: Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position. NOTE: To prevent heat damage or damage to the wire cover, please observe the following: ^ Fasten the engine No. 2 wire 30 mm (1.2 in.) or more apart from the exhaust manifold. ^ Fasten the engine No. 2 wire 17 mm (0.67 in.) or more apart from the front suspension tower. ^ Fasten the engine No. 2 wire at an angle of 30° or less behind the engine wire. HINT: At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the Page 1964 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 4286 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. Page 1014 Fuse Block: Connector Views J/B No.1 - Lower Finish Panel Page 2182 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 2192 ^ 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 3113 b. Check the spider bearing axial play. Maximum bearing axial play: 0.05 mm (0.0020 inch) HINT: ^ install new spider bearings on the shaft side in the procedure described above. ^ When replacing the propeller shaft spider on pre runner and rear propeller shaft spider on 4WD vehicles, be sure that the grease fitting assembly hole is facing in the direction shown in the illustration on the next page. Locations Multiple Junction Connector: Locations EA1 - EF1, EA - EC IF1 - IL2, IE - IH Page 264 Air Bag Control Module: Service and Repair 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 FRONT CONSOLE BOX Page 2257 Engine The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT 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 2914 Step 1 - 2 Page 2669 Knock Sensor Part 2 Page 4635 Expansion Valve: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE EXPANSION VALVE Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator and tubes. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) HINT: At the time of installation, please refer to the following item. Lubricate 4 new O-rings with compressor oil and install the tubes and valve. INSTALLATION Installation is in the reverse order of removal. Page 3838 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Page 1294 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Page 4382 Page 1990 Terminals Of ECM/ Pinouts Part 2 Page 1621 Engine Bank Identification Page 4549 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Specifications Crankshaft Gear/Sprocket: Specifications Crank pin diameter STD ..................................................................................................................................................... .......... 54.987 - 55.000 mm (2.1648 - 2.1654 inch) U/S 0.25 ........................................................................................................................................................ 54.745 - 54.755 mm (2.1553 - 2.1557 inch) Crank pin taper and out-of-round Maximum ............................................................................................................................................. .......................................... 0.02 mm (0.0008 inch) Page 1582 Engine Page 2067 CHART 27 Locations Relay Box: Locations R/B No.2 - Engine Compartment Left Page 3925 J/B No.1 Part-2 Page 1331 Engine Locations Air Flow Meter/Sensor: Locations Engine Page 3164 El - Un Page 944 Refrigerant: Fluid Type Specifications Type R-134a Page 3491 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 2913 Wiring Diagram Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned on, battery positive voltage is applied to terminal IGSW of the ECM and the EFI main relay (Marking: EFI) control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI main relay. This signal causes current to flow to the coil, closing the contacts of the EFI, main relay and supplying power to terminals +B of the ECM. w/o ETCS: If the ignition switch is turned off, the ECM continues to switch on the EFI main relay for a maximum of 2 seconds for the initial setting of the IAC valve. Wiring Diagram Page 311 LH If continuity is not as specified, replace the switch. RH If continuity is not as specified, replace the switch. INSPECT DRIVER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT FRONT PASSENGER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Locations Starter Motor: Locations Page 2936 El - Un Page 4460 Part 2 Of 2 DISASSEMBLY 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. Pre runner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. 3. Pre runner: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER Specifications Connecting Rod: Specifications Thrust clearance STD ..................................................................................................................................................... .............. 0.150 - 0.330 mm (0.0059 - 0.0130 inch) Maximum ............................................................. ........................................................................................................................ 0.380 mm (0.0150 inch) Rod bend Maximum per 100 mm (3.94 inch) ................................................................................................................................................ 0.05 mm (0.0020 inch) Rod twist Maximum per 100 mm (3.94 inch) ................................................................................................................................................ 0.15 mm (0.0059 inch) Connecting rod bolt outer diameter STD ..................................................................................................................................................... .............. 7.860 - 8.000 mm (0.3094 - 0.3150 inch) Minimum .............................................................. ......................................................................................................................... 7.600 mm (2.992 inch) Connecting rod oil clearance STD ..................................................................................................................................................... .............. 0.024 - 0.053 mm (0.0009 - 0.0021 inch) O/S 0.25 ............................................................................................................................................................ 0.023 - 0.069 mm (0.0009 - 0.0027 inch) Maximum ............................................................................ ........................................................................................................... 0.08 mm (0.0031 inch) Bushing oil clearance STD ..................................................................................................................................................... .............. 0.005 - 0.011 mm (0.0002 - 0.0004 inch) Maximum ............................................................. .......................................................................................................................... 0.05 mm (0.0020 inch) Connecting rod cap x Connecting rod 1st ........................................................................................... .............................................................................................. 25 Nm (250 kgf-cm, 18 ft. lbs.) 2nd ...... .............................................................................................................................................................. ....................................................... Turn 90° Page 1372 Engine Page 1506 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 3923 Fuse: Application and ID R/B No.2 Part-1 Locations Page 774 Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH a. Check that no continuity exists between terminals 3 and 4 with the switch OFF (float up). b. Check that continuity exists between terminals 3 and 4 with the switch ON (float down). If operation is not as specified, replace the switch. Page 3409 Electronic Brake Control Module: Testing and Inspection Terminals Of ECU / Pinouts Part 1 Page 1435 ^ 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 2176 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 640 4. REINSTALL NO.2 TIMING BELT COVER Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: 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 4303 10. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY a. Place matchmarks on the control valve housing and rack housing. b. Remove the 2 bolts. c. Pull out the control valve housing with the control valve assembly. d. Remove the O-ring from the rack housing. 11. REMOVE CONTROL VALVE ASSEMBLY a. Using SST, loosen the bearing guide nut. SST 09631-20060 b. Wind vinyl tape to the control valve shaft. c. Using a plastic hammer, tap out the control valve assembly with the bearing guide nut from the control valve housing. NOTICE: Be careful not to damage the oil seal lip. d. Remove the bearing guide nut from the control valve assembly. NOTICE: Be careful not to damage the oil seal lip. e. Remove the O-ring from the bearing guide nut. 12. REMOVE CYLINDER END STOPPER a. Using SST, remove the cylinder end stopper. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. Page 4051 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 3930 J/B No.1 - Lower Finish Panel Page 667 Supplemental Restraint System Page 2163 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. Diagrams Radiator: Diagrams RADIATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 3298 Brake Bleeding: Service and Repair 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. 3. BLEED BRAKE LINE a. Connect the vinyl tube to the caliper or wheel cylinder bleeder plug. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic. b. Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. Page 2745 El - Un Page 1838 Engine Description and Operation Malfunction Indicator Lamp: Description and Operation Check the MIL. 1. The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter 2. When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. Page 1242 22. REMOVE LH CAMSHAFT TIMING PULLEY a. Using SST, loosen the pulley bolt SST 09960-10010 (09962-01010 09963-01000) b. Remove the bolt, knock pin and timing pulley 23. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 24. REMOVE NO.1 IDLER PULLET Using a 10 mm hexagon wrench, remove the pivot bolt idler pulley and plate washer. 25. REMOVE CRANKSHAFT TIMING PULL E Y Remove the timing pulley. HINT: If the pulley cannot be removed by hand use SST and a service bolt to remove the timing pulley. SST 09950-50011 (09951-05010, 09953-05020, 09954-05011) INSPECTION 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. Locations R/B No.2 - Engine Compartment Left Testing and Inspection Overdrive Indicator Lamp: Testing and Inspection CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Wiring Diagram Steering/Suspension - Vehicle Pull Repair Supplement Alignment: Technical Service Bulletins Steering/Suspension - Vehicle Pull Repair Supplement T-SB-0391-08 December 24, 2008 Repair Manual Supplement: Vehicle Pulling to One Side Service Category Suspension Section Alignment/Handling Diagnoses Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes the following TSBs: ^ 5T005-O1: Applicability has been updated to include 2008 - 2009 model year Toyota vehicles. ^ SU001-08: Applicability has been updated to include all 2002 - 2009 model year vehicles. TSB Nos. ST005-01 and SU001-08 are Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This bulletin contains general vehicle pulling diagnosis and repair procedures along with specific information to help correct pulling complaints. This information supplements Repair Manual procedures when the symptoms are: ^ The driver holds the steering wheel without exerting steering effort while driving straight ahead the vehicle drifts to the right or the left. ^ While driving straight ahead the driver has to steer either to the right or the left to maintain straight driving. Diagrams Vacuum Brake Booster: Diagrams BRAKE BOOSTER ASSEMBLY REPLACEMENT W/ RELATED COMPONENTS Page 2847 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 4709 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: Bracket deformation - Paint peeling off the bracket - Cracks, dents or chips in the case - Cracks, dents, chipping and scratches in the connector - 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 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 3682 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. Page 2034 Oxygen Sensor: 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 3120 Flex Plate: Testing and Inspection TORQUE CONVERTER CLUTCH AND DRIVE PLATE 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 (09351-32010 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 clutch and retest the clutch. Replace the converter clutch if the clutch still fails the test. 2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator, measure drive plate runout. Maximum runout: 0.20 mm (0.0079 inch) If runout is not within the specification, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tight the bolts. Torque: 3RZ-FE: 74 Nm (750 kgf-cm, 54 ft. lbs.) 5VZ-FE: 83 Nm (850 kgf-cm, 61 ft. lbs.) Page 501 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 2643 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Page 4059 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 4555 Blower Motor: Testing and Inspection INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS 2. REMOVE BLOWER MOTOR a. Disconnect the motor connector from the blower motor. b. Remove the 3 screws and motor. 3. 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. 4. INSTALL BLOWER MOTOR a. Install the motor with the 3 screws. b. Connect the motor connector to the blower motor. 5. INSTALL GLOVE COMPARTMENT PARTS Page 3979 J/B No.1 - Lower Finish Panel Page 994 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 4462 1. INSTALL NEW BEARING a. Using 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 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 the oil seal lip with MP grease. 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/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. Pre runner: 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. Specifications Control Arm: Specifications Lower suspension arm x Frame ....................................................................................................................................... 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Lower suspension arm x Lower ball joint ...................................................................................................................... 140 Nm (1,450 kgf-cm, 103 ft. lbs.) Page 3282 Bu - VSV (Except Double Cab) Page 2358 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Page 1306 Exhaust: N = T + (A - 0.32 mm (0.013 inch)) 3. Select a new shim with a thickness as close as possible to the calculated values. Page 1840 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 3663 J/B No.3 - Behind The Instrument Panel Center Page 3095 Drive/Propeller Shaft: Diagrams PROPELLER SHAFT ASSEMBLY REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 4042 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 80 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Locations Ignition Switch: Locations Ignition Switch And Key Unlock Warning Switch Page 4422 Stabilizer Bar: Diagrams FRONT STABILIZER BAR REPLACEMENT W/ RELATED COMPONENTS Page 567 Engine Page 3432 Anti-lock Brake System Page 1626 Engine Bank Identification Page 1868 Engine Page 3798 Testing and Inspection Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kOhm per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Page 842 Spark Plug: Application and ID Recommended Spark Plug DENSO made ...................................................................................................................................... .............................................................. K16TR11 NGK made ........................................................................................................................................... ...................................................... BKR5EKB-11 Page 1071 J/B No.3 - Behind The Instrument Panel Left Page 4657 Hose/Line HVAC: Testing and Inspection REFRIGERANT LINE ON-VEHICLE INSPECTION 1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Page 2161 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 3494 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. If the terminals are corroded, clean the terminals. b. Check the H-fuses, M-fuse and fuses for continuity. Page 765 Bu - VSV (Except Double Cab) w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 3464 Step 2 - 3 Page 391 Evaporator Temperature Sensor / Switch: Service and Repair THERMISTOR REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE THERMISTOR a. Disconnect the connector clamp. b. Pull out the thermistor from evaporator. INSTALLATION Installation is in the reverse order of removal. Page 1507 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 2037 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 985 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 3942 Glossary Of Terms And Symbols Part 1 Page 3844 1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2. 2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assembly mounting points on the body. Noise Coming From Broken Dash Mounting Clips 1. Remove broken clips and pins (see Figure 3) and discard. 2. Install new clips and pins where needed. 3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below. Noise Located at Airbag Assembly Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. Noise Located at ECM Remove ECM and apply EPT sealer (P/N 08231-00810) to insulate the bracket from the ECM. Noise Located at Reinforcement Bar Page 3941 Abbreviations Locations Crankshaft Position Sensor: Locations A/C - Ho Page 3993 D. Disconnect the wire clamp. E. Disconnect the 2 wire clamps and remove the engine No. 2 wire. HINT: Unlock the clamp and remove it with a long flathead screwdriver. NOTE: Be careful NOT to install the new engine No. 2 wire harness as shown in the illustration. The ground should not wrap around engine No. 2 wire harness. Page 2845 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 3408 Anti-lock Brake System Page 1001 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Page 2281 ^ 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 1335 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 to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 622 Engine Page 1000 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 4018 BN7 - BR2 (Double Cab) BN7 - BV1 (Except Double Cab) Locations Brake Light Switch: Locations El - Un Page 485 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Page 34 INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1896 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 764 Bu - VSV (Double Cab) Page 2353 Engine Page 2049 CHART 11 Locations ABS - Di Page 3607 Auxiliary Power Outlet: Electrical Diagrams Power Outlet Specifications Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 Page 1493 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 4219 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 1594 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19mm deep socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Removal and Installation Steering Gear: Service and Repair Removal and Installation Part 1 of 3 Page 3513 c. Tighten the 5 screws until there is a clearance of at least 1 mm (0.04 in.) between the brush holder cover and connector 6. INSTALL REAR END COVER a. Install the end cover with the 3 nuts. Torque: 4.5 N.m (45 kgf.cm, 39 in.lbf) b. Install the terminal insulator with the nut. Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 7. CHECK THAT ROTOR ROTATES SMOOTHLY REPLACEMENT 1. REPLACE BRUSHES a. Unsolder and remove the brush and spring. b. Run the wire of a new brush through the spring and the hole in the brush holder, and insert the spring and brush into the brush holder. Locations Door Switch: Locations ABS - Di Page 1086 Vehicle Lifting: Locations Vehicle Lift and Support Locations (Except Double Cab) Vehicle Lift And Support Locations Part 1 Page 3128 Step 1 - 2 Page 2072 Oxygen Sensor: Locations A/C - Ho Page 3785 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 3900 Page 1635 Page 1739 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 2789 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 2039 Page 1465 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 323 Anti-lock Brake System Page 4270 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 2318 El - Un Page 4783 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. Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: 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 628 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Page 1334 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19mm deep socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. 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 APPROX. 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 Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. Engine/Transmission Controls - Resetting ECM Memory Continuously Variable Transmission/Transaxle: 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 2250 Engine Page 3587 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 2437 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. A/C switch is OFF. 2. CONNECT HAND-HELD TESTER OR OBD II SCAN TOOL a. Connect the hand-held tester or OBD II scan tool to the DLC3. b. Please refer to the hand-held tester or OBD II scan tool operator's manual for further details. 3. INSPECT IDLE SPEED a. Race the engine speed at 1,000 rpm for approximately 5 seconds. b. Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT HAND-HELD TESTER OR OBD II SCAN TOOL Locations Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left Page 351 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 2321 Air-Fuel Ratio (A/F) Sensor Heated Oxygen Sensor Locations Body Control System Page 581 Engine Page 1062 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 2870 Locations Idle Air Control (IAC) Valve (w/o ETCS-i) Page 15 ABS - Di Page 3715 Multiple Junction Connector: Application and ID EA1 - EF1 IF1 - IL2 BN7 - BR2 (Double Cab) BN7 - BV1 (Except Double Cab) BU1 Page 3471 Engine Page 1645 CHART 14 Page 2539 INSPECT FUEL LEVEL WARNING SWITCH a. Apply battery positive voltage between terminals 1 and 3, and through a 3.4 W test bulb, and check that the bulbs 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 67 Relay Box: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 1658 Page 1877 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 1982 Engine Control Module: Connector Views Terminals Of ECM/ Pinouts Part 1 Page 207 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 3869 Required Tools & Material Repair Procedure Test drive and locate the source of the noise by using the palm of your hand to apply pressure on the suspect area or by grasping and holding onto the suspected source. When disassembling the dash, it is suggested that all of the identified noise reducing countermeasures be performed, as shown below. Noise Located at Defroster Duct for 2001 - 2002 Model Year Tacoma Only 1. Remove instrument panel. Refer to the Technical Information System (TIS): 2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. 2. Remove plastic defroster nozzle assembly and discard. 3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly. 4. Install the new defroster nozzle assembly. 5. Insulate all clips, pins and connectors used. NOTE: ^ Strips found in referenced Wind Noise Kit are pre-cut (290 x 5 x 4 mm) for this application. ^ One Wind Noise Kit supplies enough material to repair approximately 10 vehicles. Noise Located at Duct Mounting Pins Page 1864 Data Link Connector: Description and Operation 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 the display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the OBD II scan tool or hand-held tester to the DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. - If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 of 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. Page 1470 Steering/Suspension - Vehicle Pull Repair Supplement Alignment: Technical Service Bulletins Steering/Suspension - Vehicle Pull Repair Supplement T-SB-0391-08 December 24, 2008 Repair Manual Supplement: Vehicle Pulling to One Side Service Category Suspension Section Alignment/Handling Diagnoses Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes the following TSBs: ^ 5T005-O1: Applicability has been updated to include 2008 - 2009 model year Toyota vehicles. ^ SU001-08: Applicability has been updated to include all 2002 - 2009 model year vehicles. TSB Nos. ST005-01 and SU001-08 are Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This bulletin contains general vehicle pulling diagnosis and repair procedures along with specific information to help correct pulling complaints. This information supplements Repair Manual procedures when the symptoms are: ^ The driver holds the steering wheel without exerting steering effort while driving straight ahead the vehicle drifts to the right or the left. ^ While driving straight ahead the driver has to steer either to the right or the left to maintain straight driving. Page 4304 b. Remove the O-ring from the cylinder end stopper. 13. REMOVE STEERING RACK AND OIL SEAL a. Using an extension bar and socket wrench (24 mm), press out the rack and oil seal. NOTICE: Take care not to drop the rack. b. Remove the oil seal from the rack. 14. REMOVE OIL SEAL AND SPACER Using SST, press out the oil seal and spacer. SST 09950-60010 (09951-00360), 09950-70010 (09951-07360) INSPECTION 1. INSPECT STEERING RACK a. Using a dial indicator, check the rack for runout and for teeth wear and damage. Maximum runout: 0.3 mm (0.0118 inch) b. Check the back surface for wear and damage. 2. 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 (09951-00260), 09950-70010 (09951-07150) b. Coat a new oil seal lip with power steering fluid. Removal and Installation Compressor Clutch: Service and Repair Removal and Installation COMPRESSOR AND MAGNETIC CLUTCH Compressor And Magnetic Clutch Page 3555 Starter Motor: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. 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: 5.9 N.m (60 kgf.cm, 52 in.lbf) for 1.4 kW 9.3 N.m (95 kgf.cm, 82 in.lbf) for 1.8 kW c. Pull out the field frame with the armature from the magnetic switch assembly. HINT: At the time of reassembly, please refer to the following items. Align the protrusion of the field frame with the cutout of the magnetic switch. d. Remove the O-ring. HINT: At the time of reassembly, please refer to the following items. Use a new O-ring. 2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Page 1220 8. REINSTALL OIL PRESSURE SWITCH a. Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST, install the oil pressure switch. SST 09268-06021 Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.) 9. START ENGINE AND CHECK FOR LEAKS Page 4530 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Page 683 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 then 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 175 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 1674 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. If the resistance is not as specified, replace the sensor. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Page 1986 Step 1 - 3 Page 2583 Engine Page 2441 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1. Check the A/F sensor or heated oxygen sensor operation. 2. See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 4305 c. Using SST, press in the oil seal. SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150) NOTICE: Make sure to install the oil seal facing the correct direction. d. Coat a new bearing with molybdenum disulfide lithium base grease. e. Using SST, press in the bearing. SST 09950-60010 (09951-00330), 09950-70010 (09951-07150) 3. IF NECESSARY, REPLACE OIL SEAL a. Using SST, press out the oil seal from the bearing guide nut. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal to the bearing guide nut SST 09950-60010 (09951-00280, 09951-00360 09952-06010), 09950-70010 (09951--07100) NOTICE: Make sure to install the oil seal facing the correct direction, Page 131 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. Interior - Dash Pad Rattles Wiring Harness: Customer Interest Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Specifications Tie Rod: Specifications Tie rod end lock nut ............................................................................................................................................................. 55 Nm (560 kgf-cm, 41 ft. lbs.) Page 1403 Catalytic Converter: Testing and Inspection ON-VEHICLE INSPECTION 1. INSPECT 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 the protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT TWC HEAT INSULATOR a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and heat insulator. Page 4098 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 2661 Ignition Coil: Service and Repair Ignition Coil REPLACEMENT 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS 3. REMOVE IGNITION COILS a. Disconnect the connector from the ignition coil. b. Remove the bolt and ignition coil from the LH cylinder head. Page 986 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. Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Page 2869 ^ 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 4005 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. Page 2492 r. Stop the engine. s. 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. t. 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 u. Remove the other union bolt 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks 3. INSPECT FUEL PUMP RESISTANCE a. Pull up the LH rear seat cushion. b. Remove the floor service hole cover with the 3 screws. c. Disconnect the fuel pump connector. d. Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 0.3 Ohm at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or set plate. 4. INSPECT FUEL PUMP OPERATION a. Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operations. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. Page 1978 El - Un Page 1547 Main Relay (Computer/Fuel System): Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 200 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 2800 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. Locations Vehicle Speed Sensor: Locations Id - Wi Page 2625 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Page 4249 Power Steering Pump: Service and Repair Disassembly and Assembly Part 1 Of 2 Page 862 Part 2 Of 2 TIMING BELT REPLACEMENT W/ RELATED COMPONENTS Page 3793 Taking into account the points given above, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Symptom Simulation SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Page 1514 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 4035 J/B No.1 - Lower Finish Panel Details 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 2236 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 1905 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 4079 J/B No.3 Inner Circuit Locations Shift Interlock Relay: Locations Instrument Panel Page 4066 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 3687 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Page 532 Page 2101 ^ 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 1245 c. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 5. INSTALL RH CAMSHAFT TIMING PULLEY a. Face the flange side of the timing pulley outward. b. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. c. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Temporarily install the crankshaft pulley bolt to the crankshaft. b. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. c. Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover. SST 09960-10010 (09962-01000, 09963-01000) 7. INSTALL TIMING BELT NOTICE: The engine should be cold. a. Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b. Face the front mark on the timing belt forward. Page 2627 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Page 3954 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 4618 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 the both 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 2 GROMMETS 5. REMOVE DRAIN PIPE GROMMET 6. REMOVE GLOVE COMPARTMENT PARTS 7. REMOVE No.4 HEATER TO REGISTER DUCT Page 3804 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Removal and Installation Starter Motor: Service and Repair Removal and Installation Page 2965 El - Un Page 1622 A/F and 02 Sensor Identification Testing and Inspection Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kOhm per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Page 2339 a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 ± 50 rpm Page 3006 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 4125 Relay Box: Electrical Diagrams J/B No.1 Inner Circuit Page 2809 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 4479 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 4067 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 Page 3817 Relay Box: Electrical Diagrams J/B No.1 Inner Circuit Locations Evaporative Vapor Pressure Sensor: Locations Bu - VSV (Double Cab) Page 1813 Intake: N = T - (A - 0.18 mm (0.007 inch)) Page 2316 CHART 30 Page 848 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: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e. If the cylinder compression in 1 or more cylinders is low, pour a 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, it is likely 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 1536 Step 4 - 6 Page 2655 d. Reconnect and install the high-tension cords as shown in the illustration. Page 1612 Knock Sensor Part 1 Page 4124 J/B No.3 - Behind The Instrument Panel Center Locations Wheel Speed Sensor: Locations A/C - Ho Page 3415 Anti-lock Brake System Page 2814 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 3118 ^ 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 1775 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1. Check the A/F sensor or heated oxygen sensor operation. 2. See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 2359 Throttle Position Sensor: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Page 3818 J/B No.1 Inner Circuit Page 3318 Brake Pad: Service and Repair REPLACEMENT HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 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. Page 59 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 209 Page 1967 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). Locations Power Window Switch: Locations Body Control System Page 3635 Glossary Of Terms And Symbols Part 2 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 Locations Actuator: Locations Bu - VSV (Double Cab) Page 4049 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 866 13. REMOVE FAN BRACKET a. Remove the nut and PS pump adjusting strut. b. Remove the bolt, nut and fan bracket. 14. REMOVE CRANKSHAFT PULLEY a. Using SST, loosen the pulley bolt SST 09213-54015 (90119-08216) 09330-00021 b. Remove the SST, pulley bolt and pulley. HINT: If necessary. remove the pulley with SST and a service bolt. SST 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05031) 15. REMOVE STARTER WIRE BRACKET AND NO.1 TIMING BELT COVER a. Remove the 2 bolts and starter wire bracket. b. Remove the 4 bolts and timing belt cover. 16. REMOVE TIMING BELT GUIDE Page 4048 Relay Box: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 2475 b. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. Page 18 Step 1 - 2 Page 971 J/B No.1 Part-2 Page 4621 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 the tubes and valve. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 4488 7. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using 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 Installation is in the reverse order of removal. HINT: After installation, bleed the brake system, check the front wheel alignment and ABS speed sensor signal. Page 3577 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 450 Hazard Warning Switch: Testing and Inspection INSPECT HAZARD WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4394 c. Using SST, disconnect the tie rod end from the steering knuckle. SST 09610-20012 3. REMOVE LOWER BALL JOINT a. Remove the cotter pin and nut from the lower ball joint. Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the lower ball joint from the lower suspension arm. SST 09628-62011 HINT: At the time of installation, face the cotter pin hole of the lower ball joint forward. c. Remove the 4 bolts. d. With lifting the upper suspension arm and steering knuckle, remove the lower ball joint. HINT: At the time of installation, after removing the lower ball joint, support the upper suspension arm and steering knuckle securely. INSPECTION INSPECT LOWER BALL JOINT FOR ROTATION CONDITION a. As shown in the illustration, flip the ball joint stud back and forth 5 limes before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn each 2 - 4 seconds and take the torque reading on the 5th turn. Turning torque: 0.1 - 2.5 Nm (1 - 25 kgf-cm, 1 - 22 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment. Page 206 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 3938 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 182 ^ 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 844 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Locations Transmission Temperature Sensor/Switch: Locations A/C - Ho 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) 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 97 J/B No.3 Inner Circuit Service Data Drive/Propeller Shaft: Specifications Service Data SERVICE DATA Page 2135 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 4202 Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -40 mm (-1.57 inch) Tire size: P265/70R16 111S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Front wheel P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ............................................. -39 mm (-1.54 inch) VZN195L-PRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 67 mm (2.64 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -23 mm (-0.91 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 68 mm (2.68 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -20 mm (-0.79 inch) RZN196L-CRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -46 mm (-1.81 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 48 mm (1.89 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -41 mm (-1.61 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) P265/70R16 111S Rear: C*3 - D*4 .................................................................................................................................... ....................................... -40 mm (-1.57 inch) Tire size: P265/70R16 111T Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) RZN196L-PRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 66 mm (2.60 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -23 mm (-0.91 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 77 mm (3.03 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -19 mm (-0.75 inch) ^ Camber ............................................................................................................................................. ............................ Right - left error: 30' (0.5°) or less RZN161L models ................................................................................................................................. ....................................... 0°18' ± 45'(0.3° ± 0.75°) VZN1701-models Except double cab models Normal ................................................................................................................................................. ................................ 0°18' ± 45' (0.3° ± 0.75°) Off-road package ....................................................... ........................................................................................................... 0°06' ± 45' (0.1° ± 0.75°) Double cab models Normal ................................................................................................................................................. ................................. -0°12' ± 45' (-0.2° 0.75°) Off-road package ....................................................... ........................................................................................................ -0°18' ± 45' (-0.3° ± 0.75°) RZN11711-models Normal ................................................................................................................................................. ................................. 0°18' ± 45' (0.3' ± 0.75°) Off-road package ....................................................... ........................................................................................................... 0°06' ± 45' (0.1° ± 0.75') RZN191L models ................................................................................................................................. ................................ 0°18' ± 45' (0.3° ± 0.75°) VZN195L models Except double cab models .................................................................................................................................................... 0°12' ± 45' (0.2° ± 0.75°) Double cab models Normal ................................................................................................................................................. .............................. -0°12' ± 45' (-0.2° ± 0.75°) Off-road package ....................................................... ........................................................................................................ -0°18' ± 45' (-0.3° ± 0.75°) VZN1961-models Except double cab models Normal ................................................................................................................................................. ................................ 0°18' ± 45' (0.3° ± 0.75°) Off-road package ....................................................... .......................................................................................................... 0° 12' ± 45' (0.2° ± 0.75°) Double cab models Normal ................................................................................................................................................. .............................. -0°12' ± 45' (-0.2° ± 0.75°) Off-road package ....................................................... ........................................................................................................ -0°30' ± 45' (-0.5° ± 0.75°) ^ Caster ............................................................................................................................................... .............................. Right-left error: 30' (0.5°) or less RZN161L-TRMDKAB Normal Tire size: P225/75R15 102S .............................................................................................................................................. 1°37' ± 45' (1.62° ± 0.75°) Tire size: P265/70R16 111S .............................................................................................................................................. 1°38' ± 45' (1.63° ± 0.75°) Page 2322 Oxygen Sensor: Service Precautions MAINTENANCE PRECAUTIONS Precautions when the handling oxygen sensors. 1. Do not allow oxygen sensor to drop or hit against an object. 2. Do not allow the sensor to come into contact with water. Page 4780 Impact Sensor: Locations Front Airbag Sensor Page 2466 Fuel Injector: Diagrams Injector Part 1 Page 1713 Engine Page 1391 Water Pump: Diagrams Part 1 Of 3 Page 1913 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 1592 Automatic Transmission Page 3792 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 1891 ^ 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 3379 Brake Master Cylinder: Diagrams BRAKE MASTER CYLINDER REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 1647 CHART 16 CHART 17 Page 3746 Step 2 - 4 Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. Diagnostic Trouble Code Chart DIAGNOSTIC TROUBLE CODE CHART w/ ECTS-I Throttle Body: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 4119 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 3738 Glossary Of Terms And Symbols Part 1 Page 675 Supplemental Restraint System Page 521 A/F and 02 Sensor Identification Page 2160 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 4120 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 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 3698 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. Locations Specifications Wheel Fastener: Specifications Wheel Nut Torque: 110 Nm (11.5 kgf.m, 83 ft. lbs) Page 630 c. Disconnect the vacuum hose from the throttle opener and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. 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 1558 Fuel Pump Relay: Testing and Inspection EFI Main Relay INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. Interior - Dash Pad Rattles Wiring Harness: All Technical Service Bulletins Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Page 901 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 1333 Engine Coolant Temperature (ECT) Sensor Page 434 Brake Light Switch: Testing and Inspection Stop Light Switch Circuit Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the ECU. When the ECU receives this signal, it cancels the cruise control. A fail-safe function is provided so that the cancel functions normally even when there is a malfunction in the stop light signal circuit. The cancel conditions: Battery positive voltage at terminal STPWhen the brake is on, battery positive voltage is normally applied through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control off. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch circuit is cut mechanically by the stop light switch and turning the cruise control off. Wiring Diagram Page 1397 a. Remove the 4 nuts and fan from the fluid coupling. 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: 7.4 Nm (75 kgf-cm, 65 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. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block. 1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. 2. Thoroughly clean all components to remove all the loose material. 3. Using a non-residue solvent, clean both sealing surfaces. b. Apply seal packing to the water pump groove 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 the water pump with the 7 bolts. Page 138 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 2684 Engine Symptom Related Diagnostic Procedures Problem Symptoms Table - Ignition Switch and Key Unlock Warning Switch Page 3652 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 Page 511 Knock Sensor Part 1 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 4092 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 2702 Knock Sensor: Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor SST 09817-16011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Locations Fusible Link: Locations R/B No.2 - Engine Compartment Left Page 4117 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 1971 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. 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 Page 4718 - 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 445 Body Control System Page 1519 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 Airbag Sensor Assembly Page 2650 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. c. Reinstall the sensor. Page 1169 SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4. Using a small screwdriver and magnetic finger, remove the adjusting shim. b. Determine the replacement adjusting shim size by following the Formula or Charts: 1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a new shim so the valve clearance comes within the specified value. T .......................................................................................................................................................... ........................ Thickness of used shim A ........................................................................................... .................................................................................. Measured valve clearance N ............................ ...................................................................................................................................................... Thickness of new shim Page 3584 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER - Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should be read thoroughly. - If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1. If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus(+)line) or ECU power circuit of the vehicle. 2. If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's Manual. Customer Problem Analysis CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. So as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis What..................................................................................................................................................... .......................................Vehicle model, system name When.............................................................. ......................................................................................................................Date, time, occurrence frequency Where.................................................................................................................................. ............................................................................Road conditions Under what conditions?...............................................................................................................Running conditions, driving conditions, weather conditions How did it happen?................................................ .....................................................................................................................................Problem symptoms Page 4470 Vehicle Lift And Support Locations Part 2 Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Testing and Inspection Expansion Valve: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE 2. SET ON MANIFOLD GAUGE SET 3. RUN ENGINE a. Run the engine at 1 ,500 rpm for at least 5 minutes. b. Then check that the high pressure reading is 1.37 - 1.57 MPa (14 - 16 kgf/sq.cm, 199 - 228 psi). 4. 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 low pressure drops to 0 kPa (0 kgf/sq.cm, 0 psi), check the receiver's IN and OUT sides for no temperature difference. Page 3786 Abbreviations Page 3646 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 3990 Repair Procedure 1. Disconnect Negative Battery Terminal. 2. Disconnect Engine No. 2 Wire Harness (Under Hood). A. Remove the bolt, and disconnect the ground strap. B. Remove the nut, and disconnect the wire from the relay block No. 2. HINT: Push upward on the clamp to remove it. C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal. Locations Door Switch: Locations ABS - Di Page 925 Fluid - Differential: Fluid Type Specifications Differential oil Oil grade ....................................................................................................................... ................................................................ Hypoid gear oil API GL-5 Viscosity Above -18° C (0° F) .... .............................................................................................................................................................. ................. SAE 90 Viscosity Below -18° C (0° F) ............................................................................................................................................................ SAE 80w or 80w-90w Page 3559 Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate. c. Remove the 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), packing, O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper. d. Temporarily install these new terminal 30 kit parts: 1. Insulation paper 2. Terminal insulator (inside) NOTE: Be careful to install the terminal insulator (inside) in the correct direction. 3. Contact plate 4. Terminal bolt 5. O-ring 6. Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them. HINT: Match the protrusion of the insulator with the indentation of the housing. 7. Wave washer 8. Terminal nut Page 4194 When it is determined by troubleshooting that the vehicle pulling to one side is caused by wheel alignment perform repairs according to the following procedure. NOTE ^ Keep the cross camber within 10 or less. ^ Keep the camber of each wheel within specifications (+/-45' of center value). ^ If adjustment exceeds the specifications, uneven tire wear will result. 3. Vehicle Pulling Caused by Tire Conicity. When it is determined by troubleshooting that the vehicle pulling to one side is caused by tire conicity perform repairs according to the following procedures. Indication of Tire Conicity as a Cause: When the front tires are switched, the pulling direction changes. Proceed to step 3A below. A. Remove the front left tire from the wheel and reverse the tire. Then perform a road test and check for change in the pulling direction. Page 592 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 3228 El - Un Page 1462 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 546 CHART 16 CHART 17 Page 2310 CHART 26 Page 2835 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 1073 Relay Box: Electrical Diagrams J/B No.1 Inner Circuit Page 3936 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 indicated by the shaded region. 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. O: SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. Page 4522 1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (Figure 4) to complete this operation. 2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5). 3. Loosen No. 2 brace by removing top bolt. 4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place. 5. Place felt insulation from Noise Kit (P/N 08231-00801) at each end of the reinforcement bar to eliminate the source of the noise. 6. Reinstall reinforcement bar, junction block, steering column and ECM. For assembly instructions, please refer to the Technical Information System (TIS): 2004 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel. For torque specifications, please refer to TIS: 2004 model year Tacoma Repair Manual: Service Specifications: Body. Noise From Wiring 1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231-00810). 2. Use foam to insulate all plastic connectors on wiring harness that may be potential sources of noise from Wind Noise Kit (P/N 08231-00810). Noise From HVAC Cables 1. Make sure cables are properly secured to the mounting brackets. 2. Wrap cables with foam from Wind Noise Kit (P/N 08231-00810). Noise From Radio Bezel Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356). Noise From "A" Pillar Wrap the "A" pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356). Locations Crankshaft Position Sensor: Locations A/C - Ho Page 3065 a. Position 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 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. REMOVE OUTER OIL SEAL Using SST, remove the oil seal. SST 09308-00010 6. REPLACE REAR AXLE BEARING Page 627 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Locations Throttle Position Sensor: Locations Id - Wi Page 1244 NOTICE: Never hold the tensioner push rod facing downward. c. Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 inch) If the protrusion is not as specified, replace the tensioner. INSTALLATION 1. INSTALL CRANKSHAFT TIMING PULLEY a. Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. b. Slide on the timing pulley, facing the flange side inward. 2. INSTALL NO.1 IDLER PULLEY a. Using a 10 mm hexagon wrench, install the plate washer and idler pulley with bolt. Torque: 35 Nm (350 kgf-cm, 26 ft. lbs.) b. Check that the pulley bracket moves smoothly. 3. INSTALL NO.2 IDLER PULLEY a. Install the idler pulley with the bolt. Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.) b. Check that the idler pulley moves smoothly. 4. INSTALL LH CAMSHAFT TIMING PULLEY a. Face the flange side of the timing pulley outward. b. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. 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 Page 2277 Engine Bank Identification Page 3753 Resistance: 1 Mohm or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. VISUAL CHECK AND CONTACT PRESSURE CHECK a. Disconnect the connectors at both ends. b. Check for rust or foreign material, etc. in.the terminals of the connectors. c. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. d. Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform "(a) Continuity Check" or "(b) Voltage Check" to locate the section. a. Check the continuity. 1. Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector "A" and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector "A" and terminal 2 of connector "C" -> Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector "A" and terminal 1 of connector "C". Page 2065 CHART 26 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 1365 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 4338 Page 4169 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 3931 J/B No.1 - Lower Finish Panel Details Page 1583 Engine Page 4104 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 2157 ^ 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 2606 Throttle Body: Testing and Inspection w/o ECTS-I THROTTLE BODY (w/o ETCS-I) ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT DASHPOT (DP) Description and Operation Malfunction Indicator Lamp: Description and Operation Check the MIL. 1. The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter 2. When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. Page 2303 CHART 22 Page 166 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 3361 Brake Proportioning/Combination Valve: Testing and Inspection LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is the described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight) 2. INSTALL LSP & BV 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 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 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE Page 801 Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.3 ± 2 mm, 0.05 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T .............................................................................................................. 0°07' ± 12' (0.11 - ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ................................................................................................................ 0°03' ± 12' (0.06° ± 0.2°, 0.7 ± 2 mm, 0.03 ± 0.08 inch) VZN170L-PRPDKAB Except off-road package Tire size: P225/75R15 102S ................................................................................................ 0°04' ± 12'(0.07° ± 0.2°, 0.8 ± 2 mm, 0.03 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ............................................................................................................... 0°04' ± 12' (0.07° ± 0.2°, 0.9 ± 2 mm, 0.04 ± 0.08 inch) Off-road package ................................................................................................................ 0°03' ± 12' (0.06° ± 0.2°, 0.8 ± 2 mm, 0.03 ± 0.08 inch) RZN171L-CRMDKAB Except off-road package Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.05 ± 0.08 inch) Tire size: P265/75R16 111S, P265/70R16 111T ............................................................................................................... 0°08' ± 12' (0.13° ± 0.2°, 1.6 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ............................................................................................................... 0°02' ± 12' (0.04° ± 0.2 °, 0.5 ± 2 mm, 0.02 ± 0.08 inch) RZN171L-CRPDKAB Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/75R16 111S, P265/70R16 111T ............................................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.5 ± 2 mm, 0.06 ± 0.08 inch) RZN191L-TRPDKAB Tire size: P225/75R15 102S ............................................................................................. 0° 07' ± 12' (0.12° ± 0.2 °, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111S .................................................................................................................. 0°08' ± 12' (0.8° ± 0.2', 1.6 ± 2 mm, 0.06 ± 0.08 inch) VZN195L-CRPDKAB Except off-road package Tire size: P225/75R115 102S ........................................................................................ 0 ° 06' ± 12' (0.10 ° ± 0.2 °, 1.1° ± 2 mm, 0.04 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111S ............................................................................................................... 0°06' ± 12' (0.10° ± 0.2°, 1.2 ± 2 mm, 0.05 ± 0.08 inch) Off-road package ................................................................................................................ 0°04' ± 12' (0.07° ± 0.2°, 0.8 ± 2 mm, 0.03 ± 0.08 inch) VZN195L-PRPDKAB Normal Tire size: P225/75R15 102S ............................................................................................... 0°04' ± 12' (0.07° ± 0.2°, 0.9 ± 2 mm, 0.04 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ............................................................................................................... 0°04' ± 12' (0.07° ± 0.2°, 1.0 ± 2 mm, 0.04 ± 0.08 inch) Off-road package ..................................................................................................................... 0°03' ± 12' (0.06° ± 0.2 °, 0.8 ± 2 mm, 0.03 ± 0.08 inch) RZN196L-CRPDKAB Except off-road package Tire size: P225/75R15 102S ............................................................................................... 0°07' ± 12' (0.12° ± 0.2°, 1.4 ± 2 mm, 0.06 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ................................................................................................................. 0°08' ± 12' (0.8° ± 0.2°, 1.6 ± 2 mm, 0.06 ± 0.08 inch) Off-road package ............................................................................................................... 0°04' ± 12' (0.07° ± 0.2 °, 0.8 ± 2 mm, 0.03 ± 0.08 inch) RZN196L-PRPDKAB Normal Tire size: P225/75R15 102S ................................................................................................ 0°04' ± 12' (0.07° ± 0.2', 1.0 ± 2 mm, 0.04 ± 0.08 inch) Tire size: P265/70R16 111S, P265/70R16 111T ................................................................................................................. 0°05' ± 12' (0.08° ± 0.2°, 1.1. 2 mm, 0.04 ± 0.08 inch) Off-road package .................................................................................................................................. 0° 00' ± 12' (0° ± 0.2°, 0 ± 2 mm, 0 ± 0.08 inch) Wheel angle (max.) Inside wheel ......................................................................................................................................... ...................... 35°05' - 38°05' (35.08 - 38.08°) Outside wheel: Reference .......................................... .......................................................................................................................... 32°20' (32.33°) Page 4009 7. Install New Engine No. 2 Wire Harness (Under Vehicle). NOTE: Reuse the following parts. (1) Positive (+) terminal cover (2) Alternator wire cover (3) Starter wire cover A. Install the new engine No. 2 wire harness and connect the 2 wire clamps. B. Connect the wire clamp. C. Connect the starter connector. Locations El - Un Locations Instrument Panel Page 3835 H. Connect the wire to the relay block No. 2 with a nut. Torque: 5 - 15 N.m (51 - 153 kgf.cm, 44 - 133 in.lbf) HINT: Install the clamp by pushing it down. I. Connect the connector to the relay block No. 2. J. Connect the 2 wires to the positive (+) terminal with a nut. Torque: 10 - 16 N.m (100 - 160 kgf.cm, 87 - 139 in.lbf) NOTE: Be sure to put the positive (+) terminal cover on. Page 4698 Refrigerant Pressure Sensor / Switch: Testing and Inspection ON-VEHICLE INSPECTION 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT PARTS 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Disconnect the pressure switch connector. b. Using an ohmmeter, check that there is continuity between the terminals. c. When refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 3751 - For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures. - When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. - The instructions "Check wire harness and connector" and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector; a connector terminal pulled out, etc. HINT: - It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators - Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Locations Starter Relay: Locations R/B No.2 - Engine Compartment Left Page 2731 Step 5 INSPECTION PROCEDURE Page 21 Terminals Of ECU /pinouts Part 1 Terminals Of ECU /pinouts Part 2 Page 4461 a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using 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/ spacer. 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 2534 Fuel Supply Line: Service and Repair FUEL SYSTEM a. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) b. 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 and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09023-38400 Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 2253 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 786 Warranty Information NOTE OP Code 044184 and the above combination codes apply to all models with the EXCEPTION of Combo E for the MR2 Spyder model. APPLICABLE WARRANTY ^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 12 months or 20,000 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. Contents This bulletin is divided into the following sections: ^ Wheel Alignment and Tire Characteristics ^ Repair Procedure Flow Chart ^ Repair Procedure ^ Important Notice ^ Troubleshooting ^ Vehicle Pulling Caused by Wheel Alignment ^ Vehicle Pulling Caused by Tire Conicity Camber Adjustment Method Wheel Alignment & Tire Characteristics 1. Relationship Between Wheel Alignment and Vehicle Pulling to One Side Page 2546 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket HINT: At the time of installation, please refer to the following items. Place a new gasket on the throttle body. INSPECTION INSPECT IAC VALVE OPERATION a. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check that the valve is closed. b. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check that the valve is open. If operation is not as specified, replace the IAC valve. INSTALLATION Installation is in the reverse order of removal Page 2469 HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. f. Connect a TOYOTA hand-held tester to the DLC3 g. 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 sec. Difference between each injector: 1.3 cu.cm (0.08 cu in.) or less If the injection volume is not as specified, replace the injector. 3. 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. c. Disconnect the negative (-) terminal cable from the battery. d. Remove the SST. SST 09268-41047, 09842-30070 e. Disconnect the TOYOTA hand-held tester from the DLC3 Steering/Suspension - Ball Joint Inspection Ball Joint: All 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 2388 Bu - VSV (Except Double Cab) Page 2136 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 3512 a. Install the 4 rubber insulators on the lead wires. NOTE: Be careful of the rubber insulators installation direction. b. Install the rectifier holder while pushing it with the 4 screws. Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf) 5. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR a. Install the brush holder cover to the brush holder. NOTE: Be careful of the holder installation direction. b. Install the voltage regulator and brush holder to the rear end frame horizontally as shown in the illustration. HINT: Check that the brush holder's cover doesn't slip to one side during installation. Page 4345 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 4792 a. Install the front airbag sensor with the 2 bolts and 2 nuts with the arrows on the sensors facing toward the front of the vehicle. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) 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 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. 2. INSTALL BATTERY a. Install the battery carrier and battery. b. Install the battery clamp with the bolt. Page 4386 Ball Joint: Specifications Front Upper ball joint turning torque .................................................................................................................... 0.7 - 4.4 Nm (7 - 45 kgf-cm, 6 - 39 inch lbs.) Lower ball joint turning torque ................................................................................................................... 0.1 - 2.5 Nm (1 - 25 kgf-cm, 1 - 22 inch lbs.) Lower ball joint excessive play Max. ..................................................................................................................................................... ........................................ 0.5 mm (0.020 inch) Steering knuckle x Lower ball joint ...................................................................................................................................... 80 Nm (820 kgf-cm, 59 ft. lbs.) Tie rod end x Lower ball joint .............................................................................................................................................. 90 Nm (930 kgf-cm, 67 ft. lbs.) Upper suspension arm x Upper ball joint ........................................................................................................................ 105 Nm (1,100 kgf-cm, 80 ft. lbs.) Lower suspension arm x Lower ball joint ...................................................................................................................... 140 Nm (1,450 kgf-cm, 103 ft. lbs.) Page 1748 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 1846 Engine Page 2014 Engine Page 476 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 2302 CHART 21 Page 1523 Page 3758 a. Remove the blown fuse and disconnect all loads of the fuse. b. Connect a test light in place of the fuse. c. Establish conditions in which the test 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) Page 711 Step 2 - 3 Page 3783 Example : Ground point "BO" is described and is installed on the back panel center. V: Indicates the reference showing the position of the splice points on the vehicle. Example : Splice point "I5" is on the Cowl Wire Harness and is described. 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.) B: Junction Connector Indicates a connector which is connected to a short terminal. Junction connector in this manual 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 a wire harness from a different part.) Wire harness sharing the same short terminal grouping have 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. Page 218 Terminals Of ECM/ Pinouts Part 2 Page 4343 Page 239 Engine Specifications Piston: Specifications Piston diameter STD Mark 1 ..................................................................................................................................................... 93.356 - 93.366 mm (3.6754 - 3.6758 inch) Mark 2 ..................................................................................................................................................... 93.367 - 93.376 mm (3.6759 - 3.6762 inch) Mark 3 ..................................................................................................................................................... 93.377 - 93.386 mm (3.6951 - 3.6766 inch) O/S 0.50 ........................................................................................................................................................ 93.856 - 93.886 mm (3.6951 - 3.6963 inch) Page 519 Page 2593 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Diagrams Heater Core Case: Diagrams Heater Unit (Part 1) Page 2771 Automatic Transmission Page 884 Assenmacher Specialty Tools 1-800-525-2943 Page 2177 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. 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 APPROX. 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 Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. Component Tests and General Diagnostics Cruise Control Module: Component Tests and General Diagnostics ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc., when terminal GND and the cruise control ECU case are grounded. Wiring Diagram Page 3583 Auxiliary Power Outlet: Diagnostic Aids How To Proceed With Troubleshooting HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure given. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. General Information GENERAL INFORMATION A large number of ECU controlled Systems are used in the TOYOTA TACOMA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. Page 3775 J/B No.1 - Lower Finish Panel Page 2660 c. Inspect the primary coil resistance. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) terminals. If the resistance is not as specified, replace the ignition coil. d. Remove the ignition coils. e. Inspect the secondary coil resistance. Using an ohmmeter, measure the resistance between the positive (+) and high-tension terminals. If the resistance is not as specified, replace the ignition coil. f. Reinstall the ignition coils. g. Reconnect the ignition coil connectors and the high-tension cords. h. Reinstall the air cleaner hose. Page 2468 Fuel Injector: Testing and Inspection INSPECTION 1. INSPECT INJECTOR RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: Approx. 13.8 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the injector. 2. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. a. Disconnect the fuel inlet pipe from the fuel tube. b. Connect SST (attachment and hose) to the fuel tube. SST 09268-41047 (09268-52011) c. Connect the fuel return hose, SST (union) and SST (hose) to the fuel pressure regulator. SST 09268-41047 (09268-41091) d. Connect SST (hose) to the injector. SST 09268-41047 e. Put the injector into the graduated cylinder. Service and Repair Fuel Line Coupler: Service and Repair FUEL SYSTEM Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push 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. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 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. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 602 Bu - VSV (Except Double Cab) Locations Knock Sensor: Locations Id - Wi Page 2286 Page 4243 Part 2 Of 2 POWER STEERING VANE PUMP REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 4766 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 connector of the SST to the airbag connector of the spiral cable. SST 09082-00700 NOTE: To avoid damaging the connector of the SST and wire harness, do not lock the secondary lock of the twin lock. 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. 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. 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. - When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. Page 4483 Part 2 Of 2 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 3965 "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 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. "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 3558 2. REPLACE REAR BEARING 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 09820-00031 3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS a. Remove the 3 bolts, lead clamp (1.8 kW) end cover, gasket and plunger. b. Using vernier calipers, measure the contact plate for depth of wear. Locations Knock Sensor: Locations Id - Wi Page 3209 Terminals Of ECM/Pinouts Part 1 Terminals Of ECM/Pinouts Part 2 Page 3733 Diagram Legend Diagram Legend O: Explains the system outline. P: Indicates values or explains the function for reference during troubleshooting. Q: Indicates the reference showing the position on the vehicle of the parts in the system circuit. Example : Part "L4" (Light Failure Sensor) The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. R: Indicates the reference showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector "1" is described and is installed on the left side of the instrument panel. S: Indicates the reference showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector "3C" connects the Instrument Panel Wire and J/B No.3. It is described and is installed on the instrument panel left side. T: Indicates the reference describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector "IE1" connects the floor wire (female) and Instrument panel wire (male). It is described and is installed on the left side kick panel. U: Indicates the reference showing the position of the ground points on the vehicle. Page 1126 Vehicle Lifting: Service and Repair Vehicle Lift And Support Locations Part 1 Page 2051 CHART 14 Page 797 Front: A*1 - B*2 ................................................................................................................................... .......................................... 41 mm (1.61 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) VZN170L-PRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 68 mm (2.68 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -20 mm (-0.79 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 69 mm (2.72 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -17 mm (-0.67 inch) RZN171L-CRMDKAB Normal Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... ......................................... 39 mm (1.54 inch) P265/70R16 111S Rear: C*3 - D*4 .................................................................................................................................... ....................................... -44 mm (-1.73 inch) Tire size: P265/70R16 111T Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -43 mm (-1.69 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 52 mm (2.05 inch) Rear C*3 - D*4 ............................................................ ................................................................................................................ -38 mm (-1.50 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -38 mm (-1.50 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) RZN171L-CRPDKAB Normal Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -43 mm (-1.69 inch) Tire size: P265/70R16 111S Front: A*1. B*2 ..................................................................................................................................... ......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ............................................................ ............................................................................................................... -44 mm (-1.73 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -38 mm (-1.50 inch) Tire size: P265/70R16 111S Front: A*1 - B*2 ................................................................................................................................... .......................................... 40 mm (1.57 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -39 mm (-1.54 inch) RZN191L-TRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ............................................................................................................... -46 mm (-1. 18 inch) Heavy-duty leaf spring Tire size: P225/75R15 102S Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -42 mm (-1.65 inch) Tire size: P265/70R16 111S, Front: A*1 - B*2 ................................................................................................................................... .......................................... 39 mm (1.54 inch) P265/70R16 111T Rear: C*3 - D*4 .................................................................................................................................... ....................................... -43 mm (-1.69 inch) VZN195L-CRPDKAB Normal Front: A*1 - B*2 ................................................................................................................................... .......................................... 42 mm (1.65 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -46 mm (-1.81 inch) Off-road package Front: A*1 - B*2 ................................................................................................................................... .......................................... 47 mm (1.85 inch) Rear: C*3 - D*4 ........................................................... ................................................................................................................ -41 mm (-1.61 inch) Heavy-duty leaf spring Page 2026 Locations Automatic Transmission 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 788 if the steering wheel is held without exerting steering effort for 109 yards (100 m) when traveling at 62 mph (100 km/h), the vehicle may drift as much as 5 feet (1.5 m). ^ When vehicle pulling is due to conicity, the amount of drift can be reduced and the direction of drift can be changed by changing the location of the tire or reversing the tire when installing it on the wheel. Repair Procedure Flow Chart Repair Procedure IMPORTANT NOTICE Before repairing vehicle pulling to one side, it is necessary to clearly identify the cause of the pulling condition. Frequently, the cause of the vehicle pulling to one side is diagnosed as wheel alignment. However, the actual cause may be lateral force generated by the tires. Performing wheel alignment when tire force is the cause could result in the wheel alignment being set at a value outside of specifications. This would then cause other problems such as uneven tire wear; etc. 1. Troubleshooting First determine whether vehicle pulling to one side is caused by a wheel alignment problem or tire characteristics, then decide which repairs to make. A. Perform the following checks and correct as necessary. (1) Check tires for size, wear and for proper inflation pressure. (2) Check whether the vehicle is noticeably tilted backward/forward or left/right. NOTE Tilting of the vehicle produces a left-right difference in the camber and caster and can cause vehicle pulling to one side. (3) Check brakes for dragging. B. Confirm problem symptoms. Page 2369 Automatic Transmission Page 3614 Engine Compartment Instrument Panel Locations Page 2227 Engine Page 201 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 2270 Applicable Vehicles Page 2074 Engine Page 4311 d. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut. e. Using SST, install the bearing guide nut. SST 09631-20060 Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) NOTICE: Be careful not to damage the oil seal lip. f. Using a punch, stake the bearing guide nut. 8. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY a. Coat a new O-ring with power steering fluid, and install it to the control valve housing. b. Align the matchmarks on the control valve housing and rack housing, and install the control valve housing with the control valve assembly to the rack housing. c. Install the 2 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 9. INSTALL DUST COVER 10. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP a. Install the rack guide seat to the rack guide. 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, rack guide spring and rack guide spring cap. 11. ADJUST TOTAL PRELOAD a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. b. Torque the rack guide spring cap. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) c. Return the cap 19°. Locations Id - Wi Page 2428 CAUTION: - Put a shop towel under the delivery pipe. - Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45014 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3 (See step 1). h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. 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 fuel hose connections, fuel pump, fuel filter and fuel pressure regulator k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 N.m (90 kgf.cm, 80 in.lbf) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kgf/sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. Page 1602 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 3189 Shift Solenoid: Diagrams The shift solenoid identification and location in the valve body is contained in the valve body service and repair procedures and overhaul articles for most models. Page 3702 D. Connect the starter wire with a nut. Torque: 8 - 12 N.m (80 - 120 kgf.cm, 70 - 104 in.lbf) E. Connect the 2 wire clamps. F. Connect the alternator connector and clamp. G. Connect the alternator wire with a nut. Torque: 7 - 13 N.m (70 - 130 kgf.cm, 61 - 112 in.lbf) Page 1133 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: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e. If the cylinder compression in 1 or more cylinders is low, pour a 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, it is likely 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 2057 CHART 21 Page 4786 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT 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 - 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 1727 If you have no hand-held tester, measure voltage between terminals VTA and E2 of the ECM connector d. Inspect the idle speed. 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. 2. INSPECT THROTTLE CONTROL MOTOR a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor resistance between terminal 4 (M+) and 3 (M-). Motor resistance: 0.3 - 100 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body c. Using an ohmmeter, measure the clutch resistance between terminal 2 (CL-) and 1 (CL+). Clutch resistance: 4.2 - 5.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. d. Reconnect the throttle control motor connector. 3. INSPECT THROTTLE POSITION SENSOR Page 1292 Spark Plug: Application and ID Recommended Spark Plug DENSO made ...................................................................................................................................... .............................................................. K16TR11 NGK made ........................................................................................................................................... ...................................................... BKR5EKB-11 Locations Id - Wi Page 3340 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, 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 Page 2921 Step 1 - 2 Page 3747 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Locations Cruise Control Module: Locations Instrument Panel Page 3755 1. Disconnect connectors "A" and "C" and measure the resistance between terminal 1 and 2 of connector "A" and body ground. In the case of Fig. 6: Between terminal 1 of connector "A" and body ground -> Continuity (short) Between terminal 2 of connector "A" and body ground -> No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 of connector "C". 2. Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. In the case of Fig. 7: Between terminal 1 of connector "A" and body ground -> No continuity Between terminal 1 of connector "B2" and body ground -> Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector "C". 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. 1. Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ohm or less Page 4043 How to Read Ground Points HOW TO READ GROUND POINTS 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] shown) can also be checked this way. How to Read Power Source HOW TO READ POWER SOURCE Page 3200 Wiring Diagram Page 4320 Steering Wheel: Testing and Inspection Repair For Steering Wheel Off Center 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. e. Draw a new line on the masking tape of the steering wheel as shown in the illustration. Page 2315 CHART 29 Page 3542 Starter (Part 2) Page 2195 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 639 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) b. Connect the sensor connector. Locations Id - Wi Specifications Timing Belt Tensioner: Specifications Timing belt tensioner Protrusion from housing side .................................................................................................................................... 10.0 - 10.8 mm (0.395 - 0.425 inch) Page 3921 J/B No.1 - Lower Finish Panel Details Page 3592 Locations Page 2905 Fluid - A/T: Service and Repair 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. NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. Page 2554 Engine Page 868 22. REMOVE LH CAMSHAFT TIMING PULLEY a. Using SST, loosen the pulley bolt SST 09960-10010 (09962-01010 09963-01000) b. Remove the bolt, knock pin and timing pulley 23. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 24. REMOVE NO.1 IDLER PULLET Using a 10 mm hexagon wrench, remove the pivot bolt idler pulley and plate washer. 25. REMOVE CRANKSHAFT TIMING PULL E Y Remove the timing pulley. HINT: If the pulley cannot be removed by hand use SST and a service bolt to remove the timing pulley. SST 09950-50011 (09951-05010, 09953-05020, 09954-05011) INSPECTION 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. Locations A/C - Ho Electrical - SRS And HV Wiring Repairs Wiring Harness: All 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 1471 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 3961 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. 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. c. Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 3737 Abbreviations Page 249 Engine Page 2348 Automatic Transmission Page 1525 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 2563 Circuit Opening Relay Page 4246 Part 2 Of 2 REMOVAL Page 647 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 4297 Torque: 36 Nm (365 kgf-cm, 26 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 INTERMEDIATE NO. 2 SHAFT 5. CONNECT RH AND LH TIE ROD ENDS 6. POSITION FRONT WHEEL FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 7. CENTER SPIRAL CABLE 8. 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. 9. BLEED POWER STEERING SYSTEM 10. CHECK STEERING WHEEL CENTER POINT 11. TORQUE STEERING WHEEL SET NUT Torque: 50 Nm (500 kgf-cm, 35 ft. lbs.) 12. INSTALL STEERING WHEEL PAD 13. CHECK FRONT WHEEL ALIGNMENT 14. INSTALL ENGINE UNDER COVER Tighten the 4 bolts. Page 1437 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 4740 Terminals Of ECU /pinouts 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 Page 530 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 2859 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 3920 J/B No.1 - Lower Finish Panel Locations Coolant Temperature Sensor/Switch (For Computer): Locations Engine Page 668 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-off switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the passenger airbag is disabled, OFF indicator inside the switch will light up. Locations Actuator: Locations Bu - VSV (Double Cab) Page 1659 CHART 26 Mechanical Specifications Thermostat: Mechanical Specifications Valve lift at 95°C (203°F) ................................................................................................................................... ................................. 8.5 mm (0.335 inch) or more Page 1572 Engine Page 4397 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 each 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.) REPLACEMENT 1. REMOVE UPPER BALL JOINT a. Remove the wire and boot. b. Using a snap ring expander, remove the snap ring. c. Using 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) 2. INSTALL UPPER BALL JOINT a. Using 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. INSTALLATION INSTALL STEERING KNUCKLE WITH AXLE HUB Page 3435 Wheel Speed Sensor: Diagrams Rear REAR SPEED SENSOR REPLACEMENT W/ RELATED COMPONENTS Locations Main Relay (Computer/Fuel System): Locations R/B No.2 - Engine Compartment Left Page 1968 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 2620 Engine Interior - Dash Pad Rattles Air Duct: Customer Interest Interior - Dash Pad Rattles NVH NV006-02 REVISED May 17, 2002 Title DASH PAD RATTLE REPAIR TIPS Models '01 - '04 Tacoma TSB REVISION NOTICE: January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin. Previous versions of this TSB should be discarded. Introduction Some customers may experience rattles from the dash area. The following procedures were developed to reduce noise from the dash area. Applicable Vehicles ^ 2001 - 2004 model year Tacoma vehicles. 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 Page 2349 Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor -- Go to Powertrain Management Diagrams. Locations Automatic Transmission Specifications Fluid Pan: Specifications Oil pan x Transmission ...................................................................................................................................................... 7.4 Nm (75 kgf-cm, 65 inch lbs.) Page 543 CHART 12 CHART 13 Locations R/B No.2 - Engine Compartment Left Page 1103 Part 2 Of 2 REMOVAL HINT: Pre runner is the model described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, RZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 3660 Fuse Block: Connector Views J/B No.1 - Lower Finish Panel Page 4198 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 1811 b. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). c. Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance (See step (a)). 5. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. 1. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). Page 3801 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) a. Disconnect the connectors at both ECU and sensor sides. b. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ohm or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) a. Disconnect the connectors on both ends. b. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Page 1018 Fuse Block: Electrical Diagrams J/B No.1 Inner Circuit Page 3168 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES 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 2175 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 1999 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket HINT: At the time of installation, please refer to the following items. Place a new gasket on the throttle body. INSPECTION INSPECT IAC VALVE OPERATION a. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check that the valve is closed. b. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check that the valve is open. If operation is not as specified, replace the IAC valve. INSTALLATION Installation is in the reverse order of removal Locations Crankshaft Position Sensor: Locations A/C - Ho Page 1760 Engine Page 3951 The inspection procedure is shown in the table. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown as an example. Problem Symptoms Table PROBLEM SYMPTOMS TABLE Page 3567 Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY (Marking: ST) 2. INSPECT STARTER RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. Page 3780 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. 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 the wire routing is shown in square brackets [ ]. 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. Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned on, battery positive voltage is applied to terminal IGSW of the ECM and the EFI main relay (Marking: EFI) control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI main relay. This signal causes current to flow to the coil, closing the contacts of the EFI, main relay and supplying power to terminals +B of the ECM. w/o ETCS: If the ignition switch is turned off, the ECM continues to switch on the EFI main relay for a maximum of 2 seconds for the initial setting of the IAC valve. Wiring Diagram Page 1538 Engine Control Module: Pinout Values and Diagnostic Parameters Terminals Of ECM/ Pinouts Part 1 Page 1072 J/B No.3 - Behind The Instrument Panel Center Page 3706 aligned position. M. Connect the ground strap with a bolt. Torque: 7 - 10 N.m (70 - 100 kgf.cm, 61 - 87 in.lbf) 8. Install Engine Under Cover. 9. Install Front Fender Apron Seal. 10. Install Left Front Tire. 11. Connect Negative Battery Terminal. Page 3599 2. Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. 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 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 3111 d. Using SST, install new bearings on the spider. SST 09332-25010 e. Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal widths. 7. INSTALL SNAP RING 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. TMC made 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 1577 Air Flow Meter/Sensor: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. w/ ECTS-I Throttle Position Sensor: Testing and Inspection w/ ECTS-I THROTTLE BODY (w/ ETCS-I) ON-VEHICLE INSPECTION 1. 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 2), wiring and ECM. c. Inspect the accelerator pedal position sensor. 1. Connect the 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 2344 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 1914 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 1431 ^ 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 4310 b. Using SST, torque the cylinder end stopper. SST 09922-10010 Torque: 59 Nm (597 kgf-cm, 43 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). c. Using a punch and hammer, stake the rack housing. 6. AIR TIGHTNESS TEST a. Install SST to the unions of 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 a. Coat the teflon rings with power steering fluid. b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft. c. Install the control valve assembly into the control valve housing. NOTICE: Be careful not to damage the teflon rings and oil seal lip. Page 2196 Engine Control Module: Locations Instrument Panel Page 2075 Engine Page 224 Engine Control Module: Pinout Values and Diagnostic Parameters Terminals Of ECM/ Pinouts Part 1 Page 120 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 4781 A/C - Ho Page 2017 If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Locations Accelerator Pedal Position Sensor: Locations A/C - Ho Page 3711 BU1 Page 1537 Step 6(Continued) - 8 Step 9 INSPECTION PROCEDURE Locations Crankshaft Position Sensor: Locations A/C - Ho Page 115 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 357 Engine Page 2831 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 536 CHART 1 Page 1013 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 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 Shift Interlock Relay: Locations Instrument Panel Page 2370 Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor -- Go to Powertrain Management Diagrams. Page 31 ABS - Di Page 988 Glossary Of Terms And Symbols Part 1 Page 3830 D. Disconnect the connector from the relay block No. 2. E. Disconnect the alternator connector and clamp. F. Remove the nut, and disconnect the alternator wire. G. Disconnect the 2 wire clamps. H. Raise the vehicle on a lift. Locations Camshaft Position Sensor: Locations A/C - Ho Testing and Inspection Control Module: Testing and Inspection Terminals Of ECM/Pinouts Page 77 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Page 1055 How to Use the Diagnostic Chart and Inspection Procedure HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL INSPECTION Locations Knock Sensor: Locations Id - Wi Page 2969 Shift Solenoid: Diagrams The shift solenoid identification and location in the valve body is contained in the valve body service and repair procedures and overhaul articles for most models. Locations Camshaft Position Sensor: Locations A/C - Ho Page 3935 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. 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 the wire routing is shown in square brackets [ ]. 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 1238 Part 2 Of 2 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT UPPER RADIATOR HOSE Page 2043 CHART 1 Page 263 Terminals Of ECU /pinouts Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.) 2. DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. Page 2879 Shift Solenoid: Diagrams The shift solenoid identification and location in the valve body is contained in the valve body service and repair procedures and overhaul articles for most models. Page 3055 Bu - VSV (Except Double Cab) Locations Actuator: Locations Bu - VSV (Double Cab) 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. Removal and Installation Power Steering Pump: Service and Repair Removal and Installation Part 1 Of 2 Page 1665 CHART 30 Page 1738 Camshaft Position Sensor Page 4068 inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. "Case 2" Open the secondary locking device. 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 Page 4225 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 3743 Diagnostic Trouble Code Check Procedure In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. Page 3236 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 4308 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 the ring fits to the steering rack. SST 09631-20081 NOTICE: Be careful not to damage the rings. 10. IF NECESSARY, REPLACE UNION SEATS a. Using a screw extractor, remove the 2 union seats from the control valve housing. b. Using a plastic hammer and sliding handle, lightly tap in 2 new union seats. NOTICE: Before installing the union seat, remove dust sticking to the control valve housing. 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 SPACER AND OIL SEAL a. Coat a new oil seal lip with power steering fluid. b. Using SST, press in the oil seal and spacer. Page 1728 a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the throttle position sensor connector. 4. 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: 1.2 - 3.2 Ohm at 20 °C (68 °F) If the resistance is not as specified, replace the throttle body. c. Reconnect the pedal position sensor connector. Page 1393 Part 3 Of 3 WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Page 338 Bu - VSV (Double Cab) Page 2790 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 2802 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 2187 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 566 El - Un Page 3581 Glossary Of Terms And Symbols Part 1 Testing and Inspection Leak Detection Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. HINT: Near the fuel tank. 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. Connect a voltmeter to terminals PTNK and E2, and measure the output voltage. Voltage: 3.0 - 3.6 V Page 3554 a. Disconnect the starter connector. b. Remove the nut, and disconnect the starter wire. Torque: 8.8 N.m (90 kgf.cm, 70 in.lbf) c. Remove the 2 bolts and starter. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) INSTALLATION Installation is in the reverse order of removal.