Toyota - Tundra 2wd - Workshop Manual - 2010 - 2010 (2)

Page 1019 Ambient Light Sensor: Diagrams Page 7830 Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 464 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 5191 (b) Remove the O-ring. 14. REMOVE REAR AXLE SHAFT OIL SEAL (a) Using SST, tap out the oil seal. SST : 09308-00010 NOTICE: Be careful not to damage the axle housing hole. Installation AXLE: REAR AXLE SHAFT: INSTALLATION 1. INSTALL REAR AXLE SHAFT OIL SEAL (a) Using SST and a hammer, tap in a new oil seal. SST : 09950-60020 09951-00770 SST : 09950-70010 09951-07150 (b) Apply MP grease to the lip of the oil seal. NOTICE: Do not allow foreign matter, etc. to contact the axle shaft housing hole. 2. INSTALL REAR AXLE SHAFT (a) Apply MP grease to a new O-ring. Page 9371 shake is a normal and unavoidable condition in certain situations with this type of vehicle. Please use the chart below to show customers the comparison to competitors. Also, show the vehicle driver that reducing speed by as little as 5 mph has a considerable positive effect in reducing body vibration. 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 occurrence of the specified condition described in this bulletin. Parts Information Repair Procedure 1. Test drive the vehicle and confirm the condition. Repeat remaining steps for both No.3 cab mounts. 2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is necessary to allow the cab to be raised to remove the No.3 mount. Page 3151 Spark Plug: Service and Repair Installation 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION 1. INSTALL SPARK PLUG (a) Using a 16 mm plug wrench, install the 8 spark plugs. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 2. INSTALL IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors. (3) Connect the 3 wire harness clamps. (b) for Bank 2: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors and 2 wire harness clamps. (3) Connect the water by-pass pipe with the 2 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) Page 8760 Remote Switch: Locations Navigation System (w/ USB Audio System) NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION Page 5139 (b) for Rear Differential: (1) Install a new gasket and the filler plug. Torque : 49 Nm (500 kgf-cm, 36 ft-lbf) (c) for Front Differential: (1) Using a 10 mm hexagon wrench, install a new gasket and the filler plug. Torque : 39 Nm (398 kgf-cm, 29 ft-lbf) Page 4093 (c) Temporarily install the EGR valve assembly to the intake manifold with the 2 bolts and 4 nuts. NOTICE: Be careful not to damage the intake manifold when installing the EGR valve assembly. (d) Using several steps, uniformly tighten the 2 bolts and 4 nuts in the sequence shown in the illustration. for bolt - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for nut - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 5. CONNECT NO. 13 WATER BY-PASS HOSE (a) Connect the No. 13 water by-pass hose. HINT The direction of the hose clamp is indicated in the illustration. 6. CONNECT NO. 12 WATER BY-PASS HOSE (a) Connect the No. 12 water by-pass hose. HINT The direction of the hose clamp is indicated in the illustration. 7. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 8. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 9. INSPECT FOR ENGINE COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 10. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 6362 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 840 (e) Attach the 3 clips (labeled F). NOTICE: * When installing the clips, do not twist the wire harness. * When installing the clips, securely insert them as shown in the illustration. (f) Connect the speed sensor connector (labeled G). NOTICE: Securely connect the connector. 7. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 6718 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 2952 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSTALLATION 1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Install a new O-ring to the manifold absolute pressure sensor. (b) Install the manifold absolute pressure sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) (c) Connect the manifold absolute pressure sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 5368 Standard voltage: (3) If the voltage is not as specified, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. If the voltage is normal, replace the 4WD control switch. Components Seat Heater Switch: Service and Repair Components SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System): COMPONENTS Page 4749 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 6022 (b) Using SST and a hammer, tap out the bearing. SST : 09950-60010 09951-00250 SST : 09950-70010 09951-07100 Reassembly 1UR-FE CHARGING: GENERATOR: REASSEMBLY 1. REMOVE GENERATOR DRIVE END FRAME BEARING (a) Using SST and a press, press in a new bearing. SST : 09950-60010 09951-00470 SST : 09950-70010 09951-07100 (b) Install the retainer plate with the 4 screws. Page 9040 Connectors Part 3 Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 1014 Parking Brake Warning Switch: Service and Repair Reassembly PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY 1. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the switch with the screw. Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf) Page 2369 * Never reuse the O-ring. * When placing a new O-ring on the injector, do not damage it. * Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and intake manifold as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type). (1) for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration. (2) for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector. Page 6601 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 5063 Standard: 2. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING (a) Using SST and a press, press in the bearing. SST : 09223-00010 (b) Using a snap ring expander, install a new snap ring. 3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH (a) Install the side gear shaft into the differential tube. Page 8776 Page 5366 Four Wheel Drive Selector Switch: Testing and Inspection JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION 1. INSPECT 4WD CONTROL SWITCH (a) Check the harness and connector (ECU - battery and body ground). (1) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage: (2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning, repair or replace harness or connector. If the harness or connector is normal, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. Standard resistance: (3) If there is a malfunction, repair or replace the harness or connector. (b) Check the harness and connector (switch - ECU). (1) Disconnect the A25 ECU connector. (2) Disconnect the L1 switch connector. (3) Measure the resistance according to the value(s) in the table below. Page 6737 Driver Side J/B - Cowl Side Left Page 3438 OK -- REPLACE BUS BUFFER ECU 25. CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU) (a) Disconnect the A25 4WD control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU (CANH, CANL) OK -- REPLACE 4WD CONTROL ECU 26. CHECK FOR SHORT IN CAN BUS WIRES (ECM) (a) Disconnect the A24 ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Result E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL) D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal Components Engine Temperature Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: COMPONENTS Page 4839 NOTICE: The ATF temperature can be confirmed by using the Techstream. (a) Turn the ignition switch off. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Enter the following menus: Powertrain / ECT / Data List / A/T Oil Temperature 1. (e) Check the ATF temperature. NOTICE: If the ATF temperature is higher than 59°C (138°F), turn the ignition switch off and wait until the fluid temperature drops to between 53 and 59°C (127 and 138°F). 5. FLUID LEVEL CHECK NOTICE: * It is necessary to change to temperature detection mode in order to idle the vehicle appropriately. * The ATF temperature must be between 53 and 59°C (127 and 138°F) to accurately check the fluid level. (a) When using the Techstream: Enter the following menus: Powertrain / ECT / Active Test / Connect the TC and TE1. Standard condition: Indicator lights in the combination meter blink. (b) When not using the Techstream: Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST : 09843-18040 Standard condition: Indicator lights in the combination meter blink. (c) Start the engine and idle it. NOTICE: Check that electrical systems such as the air conditioning system, audio system and lighting system are off. (d) Slowly move the shift lever from P to S, and then change the gear from 1st to 5th. Then return the shift lever to P. HINT Slowly move the shift lever to circulate the fluid through each part of the transmission. (e) Move the shift lever to D, and quickly move it back and forth between N and D (once within 1.5 seconds) for at least 6 seconds. This will activate the fluid temperature detection mode. Page 203 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 1458 Seat Position Sensor: Service and Repair Installation SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: INSTALLATION 1. INSTALL SEAT POSITION SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning (c) Using a feeler gauge 1.0 mm (0.0393 in.), install the seat position sensor. NOTICE: * If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the seat position sensor with a new one. * When installing the seat position sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. HINT Be sure that the clearance between the seat position sensor and the seat rail is within 0.6 to 1.4 mm (0.0236 to 0.0551 in.). (d) Using a T30 "TORX" socket wrench, install the seat position sensor with the screw. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (e) Make sure that the clearance between the seat position sensor and the seat rail is within 0.6 to 1.4 mm (0.0236 to 0.0551 in.). (f) Check that there is no looseness in the installation parts of the seat position sensor. (g) Connect the connector. (h) Install the seat slide position sensor protector to the seat position sensor. Locations Alarm Horn Relay: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 564 Power Window Relay: Locations Power Window Control System (w/o Jam Protection Function) WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/o Jam Protection Function): PARTS LOCATION Page 3099 Page 7871 (1) Insert the pin into the plate groove. (2) Attach the claw to install the main plate. (3) Install the 2 screws. (c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the damper servo. (d) Install the 4 screws and connect the 2 connectors. 9. INSTALL AIR DUCT (a) Install the duct with the 2 screws. 10. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY Removal and Replacement Oil Cooler: Removal and Replacement Components 1UR-FE LUBRICATION: ENGINE OIL COOLER: COMPONENTS Testing and Inspection Positive Crankcase Ventilation Valve: Testing and Inspection 1UR-FE EMISSION CONTROL: PCV VALVE: INSPECTION 1. INSPECT PCV VALVE SUB-ASSEMBLY (a) Install a clean hose to the PCV valve. (b) Check the PCV valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are hazardous to your health. (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If the result is not as specified, replace the PCV valve sub-assembly. (c) Remove the clean hose from the PCV valve. Page 4818 Transfer Case Actuator: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 3379 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 608 3. INSTALL NO. 2 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the rear bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 4. INSTALL NO. 2 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. 5. INSTALL REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 6. INSTALL REAR BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Page 6428 Power Distribution Relay: Testing and Inspection ACC Relay 1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAIN BODY ECU (ACC RELAY) (a) Measure the resistance of the ACC relay circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the main body ECU. Page 1294 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Locations Parking Assist Distance Sensor: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 7117 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Install the receiver with the bolt. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the receiver connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 7820 Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 6. REMOVE LOWER INSTRUMENT PANEL (a) for Column Shift Type: Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 7. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) for Column Shift Type: Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 9. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (a) Remove the screw and duct. 10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY Components Variable Valve Timing Actuator: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS Page 4559 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Diagrams Ignition Coil: Diagrams Page 4758 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. Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 72 Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation Page 7108 Tire Pressure Module: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the ECU with the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the ECU connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 7. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration . 8. PERFORM INITIALIZATION (a) Perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. Page 7670 Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub. 2. INSTALL COOLER BRACKET (a) Install the cooler bracket with the screw. (b) Attach the clamp. 3. INSPECT MAGNET CLUTCH CLEARANCE (a) Clamp the cooler compressor in a vise. (b) Set the dial indicator to the magnet clutch hub. (c) Connect the battery positive lead to terminal 3 of the magnet clutch connector and the negative lead to the ground wire. Turn the magnet clutch on and off and measure the clearance. Standard clearance: 0.35 to 0.60 mm (0.014 to 0.024 in.) (d) If the measured value is not within the standard clearance, remove the magnet clutch hub and adjust the clearance using compressor washers to obtain the standard clearance. Page 2694 (a) Remove the 3 bolts and water inlet housing. (b) Remove the gasket from the water pump. 10. REMOVE WATER PUMP PULLEY (a) Using SST, hold the water pump pulley. SST : 09960-10010 09962-01000 09963-01000 (b) Remove the 4 bolts and water pump pulley. 11. REMOVE WATER PUMP ASSEMBLY (a) Remove the 8 bolts, water pump and gasket. Page 191 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 3228 "Case2" 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 2795 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 5953 "Case2" 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 6486 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 2214 Tire Pressure Warning Reset Switch: Testing and Inspection TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION 1. CHECK TIRE PRESSURE WARNING RESET SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Regular Cab Fuel Pump Control Unit: Locations Regular Cab Body Page 7760 NOTICE: * Do not use a screwdriver or similar tool to disconnect the tube. * Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. (d) Remove the 2 O-rings from the suction pipe sub-assembly and liquid tube. 6. DISCONNECT INLET HEATER WATER HOSE AND OUTLET HEATER WATER HOSE (a) Using pliers, grip the claws of the clip and slide the clip. (b) Disconnect the 2 heater water hoses. 7. REMOVE FRONT WIPER MOTOR AND BRACKET (a) Remove the front wiper motor and bracket See: Wiper and Washer Systems/Wiper Motor/Service and Repair/Removal. 8. REMOVE STEERING COLUMN ASSEMBLY (a) Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal. 9. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 10. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Disconnect the clamps, connectors and wire harness. (b) Remove the 8 bolts, 2 screws and 4 nuts. Page 9063 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Components Auxiliary Power Outlet Switch: Service and Repair Components OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS Page 3471 HINT * o: DTC is memorized. * *1: Only during failure status. Page 3694 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 3319 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 6. INSPECT IGNITION SWITCH See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0617 NG -- REPLACE IGNITION SWITCH See: Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Service and Repair/Removal OK -- Continue to next step. 7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the cable from the battery positive terminal. (c) Remove the integration relay from the engine room relay block. (d) Disconnect the integration relay connectors. Page 4194 Page 9007 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 7956 Wire harness: Stripped wire harness section 1.25 mm2 or more (0.00193 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the steering pad, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2). HINT To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Install the 2 bolts with washers into the 2 bolt holes on the steering pad. Bolt: L: 35.0 mm (1.38 in.) M 6.0 mm (0.236 in.) Pitch 1.0 mm (0.0394 in.) NOTICE: * Tighten the bolts by hand until they become difficult to turn. * Do not tighten the bolts excessively. (2) After connecting SST each other, connect them to the steering pad. SST : 09082-00820 (3) Wind 3 wire harnesses at least 2 times each around the bolts installed on the left and right sides of the steering pad. Page 3072 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 8461 Alarm Module: Service and Repair Removal THEFT DETERRENT: THEFT WARNING ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE GLASS BREAKAGE SENSOR ECU Page 2317 (a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. (b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. (c) Align the No. 2 chain's yellow mark plates with the timing marks of the camshaft timing gear and camshaft timing exhaust gear, and attach the No. 2 chain to the gears as shown in the illustration. HINT The crankshaft timing gear and camshaft exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears. (d) Install the crankshaft timing sprocket to the crankshaft. (e) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear. (f) Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear. (g) Remove the pin from the No. 2 chain tensioner. 5. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH (a) Install the vibration damper with the 2 bolts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 6. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH HINT If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper. 7. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH Page 3722 Standard Voltage: NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) OK -- REPLACE ECM See: Service and Repair/Removal 5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the ignition switch connector. (c) Disconnect the cable from the battery positive (+) terminal. (d) Remove the AM2 fuse and integration relay. Components Ambient Light Sensor: Service and Repair Components LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: COMPONENTS Page 5785 Parking Brake Warning Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6768 JJ1-JL1 Page 6417 Power Distribution Module: Diagrams Voltage Inverter Locations Gear Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 9221 Front Door Panel: Service and Repair Front Door (for Regular Cab) Components ENGINE HOOD / DOOR: FRONT DOOR (for Regular Cab): COMPONENTS Page 6172 Auxiliary Power Outlet: Electrical Diagrams Power Outlet [120V] Power Outlet [120V] Page 2684 Page 6459 Locations Hood Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Components Tire Pressure Warning Reset Switch: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS Page 4603 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 6524 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 8340 System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for Regular Cab) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): ON-VEHICLE INSPECTION 1. CHECK SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the side airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 7652 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 835 (d) Remove the 3 bolts (labeled E), 3 harness clamps (labeled F) and sensor wire. 4. REMOVE FRONT SPEED SENSOR LH (a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the knuckle. 5. REMOVE FRONT SKID CONTROL SENSOR CLAMP LH (a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle. 6. REMOVE FRONT SKID CONTROL SENSOR WIRE RH (a) Disconnect the connector (labeled A) from the front speed sensor. (b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C). Front Door Courtesy Switch Door Switch: Service and Repair Front Door Courtesy Switch Components LIGHTING: FRONT DOOR COURTESY SWITCH: COMPONENTS Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2464 (a) Place 2 new gaskets on the intake manifold. (b) Place the intake manifold on the cylinder head. (c) Install and uniformly tighten the 8 bolts and 2 nuts in several steps. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) (d) Connect the fuel tube to the fuel delivery pipe LH See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions. (e) Connect the fuel tube to the fuel delivery pipe RH See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions. (f) Attach the 4 clamps to the fuel tube as shown in the illustration. (g) Attach the 3 wire harness clamps to the 3 wire harness brackets. (h) Connect the wire harness to the wire harness bracket with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (i) Connect the vacuum hose. Page 7532 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 637 (a) Connect the connector. (b) Attach the 4 clips to install the panel. 3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 3497 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU (CANH, CANL) OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal 18. CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR) (a) Disconnect the J46 center airbag sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG SENSOR (CANH, CANL) OK -- REPLACE CENTER AIRBAG SENSOR 19. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) (a) Measure the resistance according to the value(s) in the table below. Page 3071 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 843 1. INSTALL SKID CONTROL SENSOR WIRE (a) Install the sensor clamp with the nut (labeled A). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Make sure the clamp's rotation stopper touches the installation position. (b) Install the sensor clamp with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: When installing the clamp, do not twist the wire harness. (c) Attach the 7 clips (labeled C). NOTICE: * When installing the clamps, do not twist the wire harness. * When installing the clamps, securely insert them as shown in the illustration. (d) Connect the sensor connector (labeled D). NOTICE: Securely connect the connector. 2. INSTALL REAR SPEED SENSOR LH (a) Install the speed sensor (labeled A) with the nut (labeled B). Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Connect the speed sensor connector (labeled C). NOTICE: Securely connect the connector. 3. INSTALL REAR SPEED SENSOR RH (a) Install the speed sensor (labeled A) with the nut (labeled B). Page 6320 PJ1-QK1 Front Speed Sensor Wheel Speed Sensor: Service and Repair Front Speed Sensor Components BRAKE CONTROL: FRONT SPEED SENSOR: COMPONENTS Removal BRAKE CONTROL: FRONT SPEED SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT SKID CONTROL SENSOR WIRE LH (a) Disconnect the connector (labeled A) from the front speed sensor. (b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C). (c) Disconnect the connector (labeled D). Page 6910 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 5057 (b) If the drive gear or ring gear is damaged, replace them as a set. 16. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using a brass bar and hammer, tap out the bearing (outer race) and washer. 17. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING (a) Using SST and hummer, tap out the bearing (outer race). SST : 09950-70010 09951-07100 SST : 09950-60010 09951-00450 SST : 09950-60020 09951-00710 09952-06010 18. REMOVE FRONT DIFFERENTIAL CASE BEARING HINT * Measure the plate washer and note its thickness. * Tag the bearing outer races to show the location for reassembly. (a) Using SST and a press, press out the bearing (outer race) and plate washer from the bearing retainer. Service and Repair Fuel Pressure Release: Service and Repair 1UR-FE FUEL: FUEL SYSTEM: PRECAUTION CAUTION: * Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. * Do not smoke or be near an open flame when working on the fuel system. * Keep gasoline away from rubber and leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures. (1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. (2) Put a container under the connecting part of the pressure line. (3) Slowly loosen the connection. (4) Disconnect the connection. (5) Plug the connection with a rubber plug. (b) Observe these precautions when removing and installing the injectors: Page 6530 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 2460 9. REMOVE V-BANK COVER BRACKET (a) Remove the 2 bolts and bracket. 10. REMOVE V-BANK COVER PIN (a) Remove the pin from the intake manifold. 11. REMOVE STUD BOLT (a) Using an E5 "TORX" socket wrench, remove the 2 stud bolts. 12. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) (a) Disconnect the 2 vacuum hoses from the vacuum switching valve. (b) Remove the bolt and vacuum switching valve. 13. REMOVE PURGE VSV (a) Disconnect the purge line hose from the intake manifold. (b) Remove the bolt and purge VSV. Page 1498 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Front Door (for CrewMax) Front Door Panel: Service and Repair Front Door (for CrewMax) Components ENGINE HOOD / DOOR: FRONT DOOR (for CrewMax): COMPONENTS Page 3514 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING AMPLIFIER (CANH, CANL) OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY 24. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (BUS BUFFER ECU) (a) Disconnect the J59 bus buffer ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+, CAN-) OK -- REPLACE BUS BUFFER ECU 25. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (4WD CONTROL ECU) (a) Disconnect the A25 4WD control ECU connector. Page 390 Page 1878 Oil Filter: Service and Repair Replacement 1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT CAUTION: * Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. * Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents. * In order to protect the environment, used oil and used oil filters must be disposed of at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container. (c) Install a new gasket and the oil pan drain plug. Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) 2. REMOVE NO. 1 ENGINE UNDER COVER (a) Remove the 3 screws and 5 bolts. (b) Unhook the engine under cover from the vehicle body as shown in the illustration. 3. REMOVE OIL FILTER ELEMENT (a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe. Page 2347 Variable Valve Timing Actuator: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION 1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) Locations Seat Belt Buckle Switch: Locations SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 3403 B -- GO TO CAN MAIN WIRE FOR DISCONNECTION See: Symptom Related Diagnostic Procedures/CAN Communication System/Open In CAN Main Wire C -- GO TO CHECK CAN BUS LINES FOR SHORT CIRCUIT See: Symptom Related Diagnostic Procedures/CAN Communication System/Short in CAN Bus Lines A -- Continue to next step. 6. CHECK V BUS CIRCUIT +B (CANH, CANL - BAT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO +B See: Symptom Related Diagnostic Procedures/CAN Communication System/Short to B+ in CAN Bus Line OK -- Continue to next step. 7. CHECK V BUS CIRCUIT GND (CANH, CANL - CG) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO GND See: Symptom Related Diagnostic Procedures/CAN Communication System/Short to GND in CAN Bus Line OK -- Continue to next step. 8. CHECK ECUS CONNECTED TO CAN BUS (USING TECHSTREAM)* (a) Select "CAN Bus Check" from the "System Select". Page 6117 1UR-FE STARTING: STARTER (for 1.6 kW Type): REASSEMBLY 1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Apply high temperature grease to the areas of the starter pinion drive lever indicated in the illustration. (b) Install the starter pinion drive lever and rubber seal to the starter center bearing clutch. (c) Install the starter center bearing clutch together with the starter pinion drive lever and rubber seal into the starter drive housing. 2. INSTALL PLANETARY GEAR (a) Apply high temperature grease to the planetary gears and pins of the starter center bearing clutch. (b) Install the 3 planetary gears. 3. INSTALL STARTER ARMATURE ASSEMBLY (a) Install the starter armature to the starter yoke. NOTICE: The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed causing the magnet to break. 4. INSTALL STARTER BRUSH HOLDER ASSEMBLY (a) Push out the 4 brushes from the brush holder so that they are held in place by the springs, as shown in the illustration. (b) Install the brush holder to the starter armature and push in the 4 brushes. (c) Insert grommet between the positive (+) side and negative side. Page 25 (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 5. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 3426 NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (AIR CONDITIONING AMPLIFIER) OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY Problem Symptoms Table CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS TABLE HINT * Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. * Inspect the fuses and relays related to this system before inspecting the suspected areas below. Page 196 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 2859 Fuel Pump Control Unit: Service and Repair Installation 1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION 1. INSTALL FUEL PUMP ECU (a) Install the fuel pump ECU with the 2 bolts. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being dropped, etc. (b) Connect the 2 fuel pump ECU connectors. Page 3711 ^ 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 6832 Page 6770 MJ1-NP1 Page 8239 Removal SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat) (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE FRONT SEAT ASSEMBLY (for Power Seat) (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. Page 2841 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 8815 4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 5. REMOVE FRONT DOOR ARMREST COVER LH 6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 4 screws and speaker. NOTICE: Do not touch the cone part of the speaker. 9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) (a) Remove the 3 screws and speaker with bracket. (b) Detach the 3 claws and remove the speaker from the bracket. NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSTALLATION HINT * Use the same procedures for the LH side and RH side. Page 424 Fuel Pump Control Unit: Diagrams Page 5932 Yaw Rate Sensor: Service and Repair Removal BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal 3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE YAW RATE SENSOR (a) Remove the 2 nuts (labeled A) and sensor. (b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the sensor bracket. Page 4382 Fuel Pump Control Unit: Service and Repair Removal 1UR-FE FUEL: FUEL PUMP ECU: REMOVAL 1. REMOVE FUEL PUMP ECU (a) Disconnect the 2 fuel pump ECU connectors. (b) Remove the 2 bolts and fuel pump ECU. NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being dropped, etc. Page 5144 2. REMOVE PROPELLER SHAFT ASSEMBLY (a) Remove the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Removal. (b) Remove the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Removal. 3. REMOVE REAR DRIVE PINION NUT (a) Using SST and a hammer, loosen the staked part of the nut. SST : 09930-00010 (b) Using SST to hold the companion flange, remove the nut. SST : 09330-00021 09330-00030 4. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, remove the companion flange. SST : 09950-30012 09951-03010 09953-03010 09954-03010 09956-03050 SST : 09955-03050 Page 481 Seat Occupant Classification Module - Air Bag: Service and Repair Installation SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: INSTALLATION 1. INSTALL OCCUPANT CLASSIFICATION ECU (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Attach the claw and install the occupant classification ECU to the seat. NOTICE: * If the ECU has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the ECU, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the ECU. 2. INSTALL FRONT SEAT ASSEMBLY RH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. Components Ambient Temperature Sensor / Switch HVAC: Service and Repair Components AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: COMPONENTS Page 284 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 3451 NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - ECM)". (a) Measure the resistance according to the value(s) in the table below. Page 1186 Manifold Pressure/Vacuum Sensor: Diagrams Airbag Cut-OFF Switch Air Bag Deactivation Switch: Testing and Inspection Airbag Cut-OFF Switch SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSPECTION 1. INSPECT AIRBAG CUT-OFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 7651 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 6647 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab) 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal Page 8224 (b) Check if SST is functioning properly. SST : 09082-00700 SST : 09082-00770 CAUTION: When activating a seat belt pretensioner, always use the specified SST. (c) Prepare SST for activation of the seat belt pretensioner. (1) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner. NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (2) Place the front seat outer belt on the ground and cover it with a tire (with wheel). NOTICE: Set up the front seat outer belt as shown in the illustration. (3) Move SST at least 10 m (32.8 ft.) away from the wheel. NOTICE: Take care not to damage SST wire harness. Page 6189 (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL POWER OUTLET SOCKET ASSEMBLY (a) Attach the claw to install the power outlet socket. 3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) Page 3850 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS Removal 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL CAUTION: * The procedures should be performed by at least 2 people. * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Disconnect the sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Disconnect the heated oxygen sensor connector and 2 clamps. Page 5594 Electronic Brake Control Module: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 9375 10. Lower the cab back onto the No. 3 cab mount. 11. Install the new bolt through the No.3 cab mount and install the large washer and NEW nut and torque to specifications. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) 12. Torque the nuts to the specified torque range on the No.2 mounts. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) Page 5671 Yaw Rate Sensor: Service and Repair Removal BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal 3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE YAW RATE SENSOR (a) Remove the 2 nuts (labeled A) and sensor. (b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the sensor bracket. Components Lower Side Moulding / Trim: Service and Repair Components EXTERIOR: SIDE MOULDING: COMPONENTS Up to 11/2009 Parking Brake Warning Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Locations Overdrive Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION 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 6891 Power Distribution Relay: Diagrams Page 1073 Hazard Warning Switch: Testing and Inspection LIGHTING: HAZARD WARNING SWITCH: INSPECTION 1. INSPECT HAZARD WARNING SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the warning switch. (c) Connect the battery's positive (+) lead to terminal 3 and the negative (-) lead to terminal 2. (d) Check that the light comes on. OK: Light comes on (e) If the result is not as specified, replace the warning switch. Locations Relay Box: Locations Engine Compartment Page 6898 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Components Front Steering Knuckle: Service and Repair Components AXLE: STEERING KNUCKLE: COMPONENTS Page 2974 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS Removal 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL CAUTION: * The procedures should be performed by at least 2 people. * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Disconnect the sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Disconnect the heated oxygen sensor connector and 2 clamps. Page 3301 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 8435 Airbag Cutoff Switch Air Bag Deactivation Switch: Diagrams Airbag Cutoff Switch Page 6822 Page 2272 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 3440 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (DLC3 BRANCH WIRE) (a) Disconnect the J86 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step. 3. CONNECT CONNECTOR Page 5187 (a) Inspect and adjust the front wheel alignment See: Maintenance/Alignment/Service and Repair. Components AXLE: REAR AXLE SHAFT: COMPONENTS Page 4791 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 9181 3. INSTALL SIDE STEP BRACKET LH (a) Install the side step bracket with the 2 bolts. Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) 4. INSTALL STEP ARM SPACER LH 5. INSTALL STEP COVER PROTECTOR LH 6. INSTALL STEP PLATE COVER LH (a) for Double Cab: Install the step plate cover. (1) Attach the 19 clips to install the step plate cover. (b) for CrewMax: Install the step plate cover. (1) Attach the 23 clips to install the step plate cover. Page 1313 "Case2" 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 7718 Control Module HVAC: Service and Repair Removal AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE RH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE COWL SIDE TRIM BOARD RH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) for Column Shift Type: Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE INSTRUMENT SIDE PANEL RH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Page 7723 Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Check Mode Procedure. Page 2541 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 4998 (a) Install the shift solenoid valve. (b) Install the 2 straight pins and lock plate with the bolt. Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf) Page 5824 Electronic Brake Control Module: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Steering Control Module: Service and Repair Components POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS Page 903 Ambient Temperature Sensor / Switch HVAC: Diagrams Locations Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 6795 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 3479 Connect the Techstream to the vehicle, and turn a courtesy switch on and off at 1.5 second intervals until communication between the tester and vehicle begins. PROCEDURE 1. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - INTEGRATION CONTROL AND PANEL) (a) Disconnect the J37 integration control and panel assembly connector. (b) Disconnect the J19 air conditioning amplifier assembly connector. (c) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 2. CHECK HARNESS AND CONNECTOR (INTEGRATION CONTROL AND PANEL - BATTERY AND BODY GROUND) (a) Disconnect the J37 integration control and panel assembly connector. (b) Measure the resistance and voltage according to the value(s) in the table below. Standard Resistance: Standard Voltage: Page 5007 (a) Coat a new O-ring with ATF, and install it to the oil strainer. (b) Install the oil strainer with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTICE: Be careful not to spill oil on the contacting surfaces of the transmission case and oil pan. (a) Install a new gasket and the oil pan with the 20 bolts. Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf) 5. ADD AUTOMATIC TRANSMISSION FLUID (a) Add automatic transmission fluid See: Service and Repair/Procedures. Page 2835 (b) Spray gasket remover or equivalent on the remaining tape of the gasket. NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth. (c) Remove the tape of the gasket without using bladed objects. Page 120 Traction Control Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 942 7. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. 8. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the servo motor. (1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to install the main plate. (2) Install the 2 screws. (b) Install the servo motor. Page 6048 Push the terminal retainer down to the temporary lock position. Page 2014 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 6769 JQ1-LJ1 Page 4969 Transmission Position Switch/Sensor: Diagrams Page 929 Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 435 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay 1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION 1. REMOVE FUEL PUMP RELAY (F/PMP) (a) Remove the fuel pump relay from the engine room relay block. 2. INSPECT FUEL PUMP RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the fuel pump relay. 3. INSTALL FUEL PUMP RELAY (a) Install the fuel pump relay to the engine room relay block. Page 6260 Page 8624 Removal AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Double Cab: Remove the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (b) for Regular Cab: Page 4484 Throttle Position Sensor: Diagrams Page 4775 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 3916 Variable Valve Timing Actuator: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION 1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) Page 3244 Page 1221 Power Steering Pressure Switch: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT POWER STEERING OIL PRESSURE SWITCH (a) Check the oil pressure switch. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch on. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering pressure. (5) Start the engine. (6) Operate the steering wheel while idling, and read the value on the Techstream. Standard: (7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Inspect the power steering system See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Page 6280 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 5026 Page 8842 Removal AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Components Integrated Accessory Switch Assembly: Service and Repair Components METER: DRIVE MONITOR SWITCH: COMPONENTS Up to 11/2009 Parking Brake Warning Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8437 (a) Remove the antenna ornament as shown in the illustration. 3. REMOVE FENDER APRON MUDGUARD SEAL RH See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Removal 4. REMOVE FENDER ANTENNA ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and detach the 5 clamps. (c) Remove the bolt and antenna. Installation AUDIO / VISUAL: RADIO ANTENNA: INSTALLATION Page 4281 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 5146 (b) Using SST and the companion flange, install the bearing (inner race). Then remove the companion flange. SST : 09950-30012 09951-03010 09953-03010 09954-03010 09956-03050 SST : 09955-03050 11. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 12. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end. SST : 09316-12010 SST : 09649-17010 Standard oil seal depth: 0.05 to 0.95 mm (0.0197 to 0.0374 in.) HINT Connect 2 SST with vinyl tape. (b) Coat the lip of the oil seal with MP grease. 13. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Place the companion flange on the drive pinion. Page 6373 Page 5708 2. Loosen the bleeder plug. 3. Using the Techstream, operate the brake actuator, completely depress the brake pedal and hold it there. HINT The operation stops automatically after 4 seconds. When performing this procedure continuously, set an interval of at least 20 seconds. NOTICE: * During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid comes out of the bleeder plug. * Depress and hold the brake pedal. Do not depress and release the pedal repeatedly. (10)4. Tighten the bleeder plug, and then release the brake pedal. 5. Repeat the 3 previous steps until all air in the fluid is completely bled out. 6. Tighten the bleeder plug. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (11)7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure reduction line. (12)Clear the DTCs See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. (13)Inspect for brake fluid leak. (14)Check and adjust brake fluid level in reservoir See: Brake Fluid/Testing and Inspection. (15)If any DTC is set, perform the troubleshooting for the DTC (16)Check the DTC See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. Components Neutral Safety Switch: Service and Repair Components A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS Page 607 HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 14. REMOVE NO. 2 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the rear bumper. Installation PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): INSTALLATION 1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the rear bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 2. INSTALL NO. 1 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. Page 7185 (b) Inspect the vane pump plate. (1) Using a micrometer, measure the thickness of the vane pump plates. Standard thickness: 1.405 to 1.411 mm (0.05531 to 0.05555 in.) (2) If the thickness is not within the specified range, replace the vane pump plates. 3. INSPECT TOTAL PRELOAD (a) Check that the pump rotates smoothly without abnormal noise. (b) Temporarily install the service bolt. Recommended service bolt: (c) Using a torque wrench, measure the pumps rotating torque. Standard rotating torque: 0.3 N*m (3 kgf*cm, 2 in.*lbf) or less (d) If the rotating torque is not as specified, check the vane pump housing oil seal. Page 6102 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the magnet starter switch assembly. 3. INSPECT STARTER ARMATURE ASSEMBLY (a) Check the appearance. If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe. (b) Measure the resistance. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the starter armature assembly. (3) Measure the resistance according to the value(s) in the table below. Standard Resistance: (4) If the result is not as specified, replace the starter armature assembly. (c) Check the commutator circle runout. (1) Place the armature shaft on V-blocks. Locations Tire Pressure Sensor: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 839 Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) NOTICE: * Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part. * While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip part. * After installing the speed sensor, make sure there is no clearance or foreign matter between the sensor stay part and the knuckle. * Make sure there is no foreign matter attached to the magnetic rotor. 6. INSTALL FRONT SKID CONTROL SENSOR WIRE RH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). for Bolt B - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Install the connector (labeled C) with connect the connector (labeled C). (c) Install the 2 harness clamps (labeled D) with the 2 bolts (labeled E). for Bolt E - Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamps, do not twist the wire harness. * For clamps with rotation stoppers, make sure the rotation stopper touches the installation position. (d) Install the harness clamp with the bolt (labeled E). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamp, do not twist the wire harness. * Make sure the clamp's rotation stopper touches the installation position. Page 6327 PJ1-TJ1 Page 2550 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Power Mirror Control System (w/ Memory) Power Mirror Switch: Locations Power Mirror Control System (w/ Memory) MIRROR: POWER MIRROR CONTROL SYSTEM (w/ Memory): PARTS LOCATION Page 2457 Page 4894 Shifter A/T: Component Tests and General Diagnostics SHIFT LEVER ASSEMBLY (for Column Shift Type) A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): INSPECTION 1. INSPECT COLUMN SHIFT SHIFT LEVER SUB-ASSEMBLY (a) Disconnect the transmission control switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the column shift shift lever sub-assembly. SHIFT LEVER ASSEMBLY (for Floor Shift Type) A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): INSPECTION 1. INSPECT TRANSMISSION CONTROL SWITCH (a) Disconnect the transmission control switch connector. (b) Measure the resistance according to the value(s) in the table below. Page 2393 Engine Oil: Fluid Type Specifications Grade ................................................................................................................................................... ..................................... ILSAC multigrade engine oil 4.6L V8 ................................................................................................................................................ ............................................................... SAE 0W-20 5.7L V8 ................................................................................................................................................ .............................................. SAE 5W-20 or 0W-20 Page 4107 SST : 09268-31012 90467-13001 95336-08070 09268-41500 09268-41120 SST : 09268-45014 09268-41200 09268-41220 (g) Wipe off any gasoline. (h) Reconnect the cable to the negative (-) battery terminal. (i) Operate the fuel pump. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. NOTICE: Do not start the engine. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (j) Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (k) If the pressure is higher than the specification, replace the fuel pressure regulator. If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator assembly. (l) Start the engine. Page 6549 Engine Room R/B, J/B - Engine Compartment Left Page 2905 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Page 837 2. INSTALL FRONT SPEED SENSOR LH (a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E). Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) NOTICE: * Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part. * While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip part. * After installing the speed sensor, make sure there is no clearance or foreign matter between the sensor stay part and the knuckle. * Make sure there is no foreign matter attached to the magnetic rotor. 3. INSTALL FRONT SKID CONTROL SENSOR WIRE LH (a) Connect the connector (labeled A). (b) Install the 3 harness clamps (labeled B) with the 3 bolts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamps, do not twist the wire harness. * For clamps with rotation stoppers, make sure the rotation stopper touches the installation position. (c) Install the harness clamp with the bolt (labeled D). Page 6187 Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Column Shift Type) Components OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Removal OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab) Page 5065 SST : 09950-60010 09951-00420 Standard bearing depth: 1.2 to 1.8 mm (0.0472 to 0.0709 in.) 7. INSTALL FRONT DIFFERENTIAL CASE (a) Install the 2 side gear thrust washers onto the 2 side gears. HINT Using the table below, select the thrust washer which will ensure that the backlash is within the specifications. Washer thickness: (b) Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly. HINT * Align the holes of the differential case assembly and pinion shaft. * Apply hypoid gear oil to each sliding surface and rotating part. (c) Measure the side gear backlash. (1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly. Page 8181 Page 6358 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 7026 for Double Cab of Long Deck Page 3490 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR SHORT IN CAN BUS WIRES (DLC3 BRANCH WIRE) (a) Disconnect the J86 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step. 3. CONNECT CONNECTOR Page 1774 Drive Belt: Service and Repair Installation 1UR-FE ENGINE MECHANICAL: DRIVE BELT: INSTALLATION 1. INSTALL FAN AND GENERATOR V BELT (a) Set the V belt onto every part. (b) While turning the belt tensioner counterclockwise, remove the pin. NOTICE: Make sure that the V belt is properly set to each pulley. (c) After installing the belt, check that it fits properly in the ribbed grooves. HINT Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley. 2. INSTALL NO. 1 ENGINE UNDER COVER See: Fluids/Engine Oil/Service and Repair/Replacement 3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 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 8615 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 occurrence of the specified condition described in this bulletin. Required Tools & Equipment Parts Information Repair Procedure Page 2092 J/B No.5 - Instrument Panel Center Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 2184 Tire Pressure Module: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Locations Garage Door Opener Transmitter: Locations GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: PARTS LOCATION Page 916 Cabin Temperature Sensor / Switch: Service and Repair Removal AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE ROOM TEMPERATURE SENSOR Specifications Intake Manifold: Specifications INTAKE MANIFOLD Install and uniformly tighten the 8 bolts and 2 nuts in several steps. Torque.................................................................................................................................................. .....................................21 Nm (214 kgf-cm, 15 ft-lbf) Page 1469 Page 871 Cruise Control Switch: Diagrams Page 4525 Ignition Coil: Service and Repair Removal 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the MAF meter connector and clamp. (b) Disconnect the ventilation hose and vacuum hose. (c) Loosen the hose clamp. (d) Remove the 2 bolts and air cleaner. 3. REMOVE IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Disconnect the 3 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Remove the 4 bolts and 4 ignition coils. (b) for Bank 2: (1) Disconnect the 2 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Disconnect the engine wire harness clamp. Page 3236 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 8034 Air Bag Deactivation Switch: Service and Repair Curtain Shield Airbag Cutoff Switch Components SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Disconnect the connector. Heated Oxygen Sensor Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE INSPECTION 1. CHECK HEATED OXYGEN SENSOR (a) Disconnect the heated oxygen sensor connector. (b) Measure the heater resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the heated oxygen sensor. (d) Connect the heated oxygen sensor connector. Page 4177 Page 3051 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 1344 Knock Sensor: Diagrams Page 9373 5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount bolts. 6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be used in their place. Page 2098 Driver Side J/B Inner Circuit Page 2921 Crankshaft Position Sensor: Diagrams Page 4974 Transmission Speed Sensor: Testing and Inspection A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION 1. INSPECT SPEED SENSOR NT (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. 2. INSPECT SPEED SENSOR SP2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. Page 8443 (d) Detach the 2 claws and remove the satellite radio antenna. Installation AUDIO / VISUAL: SATELLITE RADIO ANTENNA: INSTALLATION 1. INSTALL SATELLITE RADIO ANTENNA ASSEMBLY (a) Attach the 2 claws to install the satellite radio antenna. (b) Install the nut. Torque : 4.5 Nm (45 kgf-cm, 39 in-lbf) (c) Attach the 3 clamps. (d) Connect the connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) for Double Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (b) for CrewMax: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 8497 Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS Page 3702 ^ 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 6261 Page 9061 Push the terminal retainer down to the temporary lock position. Page 5967 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 8302 Rear Seat Belt Extender Applications Part Number Information Owners Instructions Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision causing personal injury. If your seat belt cannot be fastened securely because it is not long enough a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please visit your local Toyota dealer so that the dealer can order the proper required length extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. Page 6400 Page 2311 Camshaft: Service and Repair Camshaft (for Bank 2) Components 1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): COMPONENTS Removal Page 2780 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Locations Dome Lamp Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Locations Cabin Temperature Sensor / Switch: Locations AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Up to 11/2009 Traction Control Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6122 (b) Install the starter brush holder. (c) Connect the 4 brushes to the starter brush holder. (1) Using a screwdriver, hold back the spring. (2) Connect the brush to the brush holder. (d) Align the rubber part on the starter yoke with the groove of the starter commutator end frame. (e) Install the starter commutator end frame with the 2 screws. Torque : 3.8 Nm (39 kgf-cm, 33 in-lbf) 5. INSTALL STARTER DRIVE HOUSING ASSEMBLY (a) Apply high temperature grease to the starter pinion drive lever as shown in the illustration. (b) Install the starter pinion drive lever to the starter center bearing clutch. (c) Align the protrusions of the starter center bearing clutch with the notches inside the starter drive housing. Testing and Inspection Radiator: Testing and Inspection 1UR-FE COOLING: RADIATOR: ON-VEHICLE INSPECTION 1. INSPECT RADIATOR CAP SUB-ASSEMBLY 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. (a) Measure the valve opening pressure. (1) If there are water stains or foreign matter on rubber packing 1, 2 or 3, clean it by using water and finger scouring. (2) Check that rubber packing 1, 2 and 3 are not deformed, cracked or swollen. (3) Check that rubber packing 3 and 4 are not stuck together. (4) Apply engine coolant to rubber packing 2 and 3. (5) Prepare a radiator cap tester, and tilt it more than 30°. (6) Pump the cap tester several times, and check the maximum pressure*. Pumping speed: 1 pump per second HINT *: Even if the cap cannot maintain the maximum pressure, it is not a defect. Standard Judgment Criterion: (7) If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. 2. INSPECT FINS FOR BLOCKAGE (a) Check that the radiator and condenser are not blocked with leaves, dirt, or insects. Clean the hose connections. Up to 11/2009 Hydraulic Control Assembly - Antilock Brakes: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Oil Filter: Service and Repair Components 1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS Page 9170 1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from front to back using the pry bar to assist. Be careful NOT to damage the chrome/painted surface. 2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and hammer to punch the plastic bits into the tube. Use an air gun to blow the posts out through the end of the tube. 3. Discard the step pad. 4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard. 5. Install the new post retainers into the holes in the tube. 6. Line up the replacement step posts with the holes in the post retainers. 7. Using the palm of your hand push firmly down in all post locations. Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly. Page 4915 7. DISCONNECT NO. 1 SHIFT LOCK PLATE SUB-ASSEMBLY (a) Using a pin-punch and hammer, tap out the spring pin and disconnect the shift lock plate from the shift lock solenoid. 8. REMOVE TRANSMISSION CONTROL SWITCH (S POSITION) (a) Remove the 2 screws and switch from the column shift control shift lever retainer. (b) Insert a thin-bladed screwdriver, release the locking lug of terminal 6 (IG) and 13 (S), and pull the terminals out from the rear. Diagrams Steering Angle Sensor: Diagrams Up to 11/2009 Acceleration/Deceleration Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 7947 CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (f) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the tires. (g) Deploy the airbag. (1) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the lower No. 1 instrument panel airbag is tied to. (3) Press SST activation switch to deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tires. HINT The airbag is deployed as the LED of SST activation switch comes on. (h) Dispose of the lower No. 1 instrument panel airbag. CAUTION: * The lower No. 1 instrument panel airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag with a deployed airbag. * Do not apply water to a lower No. 1 instrument panel airbag with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the lower No. 1 instrument panel airbag from the tire. (2) Place the lower No. 1 instrument panel airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Front Passenger Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY: DISPOSAL Page 2827 HINT The wavelength becomes shorter as the vehicle speed increases. (k) WAVEFORM 10: HINT The duty ratio varies depending on the throttle actuator operation. (l) WAVEFORM 11: HINT The duty ratio varies depending on the throttle actuator operation. (m)WAVEFORM 12: Page 5986 Neutral Safety Switch: Component Tests and General Diagnostics A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the switch assembly. Components Tire Pressure Sensor: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS Locations Tire Pressure Monitor Receiver / Transponder: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 6914 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 4271 ^ 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 7264 (a) Attach the claw to install the upper steering column cover. (b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish panel. (c) Install the 2 screws. Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf) HINT Turn the steering wheel to the right and left as necessary to install the 2 screws. 8. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 8765 Remote Switch: Service and Repair Installation AUDIO / VISUAL: STEERING PAD SWITCH: INSTALLATION 1. INSTALL STEERING PAD SWITCH ASSEMBLY (a) Attach the 4 pins to install the switch with the 2 screws. (b) Connect the connector. 2. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 3. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 4. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. INSPECT STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 7. CHECK SRS WARNING LIGHT See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation Page 8509 If the customer has experienced a RES malfunction above -22 F (-30 C) proceed with diagnosis referencing the applicable troubleshooting guide in the Technical Information System (TIS) Accessory tab Accessory Diagnostic Guide: For 2007 Camry, Camry HV; Tundra, and 2006 - 2007 RAV4: Refer also to TSB T-SB-0070-08, "Remote Engine Starter (RES) Cold Temperature Operation". Page 3056 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 4379 Fuel Pump Control Unit: Diagrams Page 136 Control Module HVAC: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Locations Sunroof / Moonroof Switch: Locations SLIDING ROOF: SLIDING ROOF SYSTEM: PARTS LOCATION Page 5761 26. REMOVE NO. 2 CABLE RETAINER (a) Remove the bolt and cable retainer. 27. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Remove the 5 bolts and disconnect the No. 3 parking brake cable from the intermediate lever. NOTICE: Do not bend and twist the parking brake cable. (b) Remove the bolt and No. 3 parking brake cable from the rear axle carrier. Page 3334 Engine Control Module: Programming and Relearning 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The Techstream is required to register the VIN. 1. DESCRIPTION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT This registration section consists of two parts: Read VIN and Write VIN. (a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read in order to confirm that the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the same. (b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM by following this procedure. 2. READ VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read. 3. WRITE VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write. Page 5969 Page 6196 3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 5. REMOVE CENTER FRONT SEAT ASSEMBLY (a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal. 6. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Disconnect the power outlet socket connector. (b) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 7. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. Page 7260 Page 3713 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 1975 Engine Room R/B, J/B - Engine Compartment Left Page 5396 Control Module: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE 4WD CONTROL ECU (a) Disconnect the 2 ECU connectors. (b) Remove the bolt and ECU. Locations Tire Pressure Sensor: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 5771 28. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1GR-FE) (a) for Regular Cab Standard Deck: Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. (b) except Regular Cab Standard Deck: Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation. 29. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1GR-FE) (a) for Regular Cab Standard Deck: Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. 30. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1UR-FE) (a) for Regular Cab Standard Deck: Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. (b) except Regular Cab Standard Deck: Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation. 31. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FE) (a) for Regular Cab Standard Deck: Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. (b) except Regular Cab Standard Deck: Page 6977 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 9107 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 7349 3. REMOVE REAR WHEEL 4. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Remove the 3 bolts and disconnect the cable from the vehicle. 5. DISCONNECT REAR SHOCK ABSORBER ASSEMBLY LH (a) Support the rear axle housing with a jack using a wooden block to avoid damage. (b) Remove the bolt and nut, and disconnect the shock absorber lower side from the axle housing. 6. REMOVE REAR SPRING U BOLT (a) Remove the 4 nuts, 4 washers and spring seat. (b) Remove the 2 U bolts. 7. REMOVE REAR SPRING BUMPER SUB-ASSEMBLY (a) Remove the spring bumper. Page 3031 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Page 8050 Clockspring Assembly / Spiral Cable: Service and Repair Removal SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD See: Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 7. REMOVE LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 9. REMOVE SPIRAL CABLE (a) Disconnect the connectors from the spiral cable with steering sensor. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Detach the 3 claws and remove the spiral cable with steering sensor. NOTICE: * Do not replace the spiral cable sub-assembly when the ignition switch is ON and the battery cable is connected. * Do not rotate the spiral cable when the ignition switch is ON and the battery cable is connected. * Make sure the steering wheel is installed and centered before rotating the steering angle sensor when performing steering angle sensor operation inspections (inspecting for abnormal noise, diagnosis inspections, etc.). * Do not remove the steering angle sensor from the spiral cable. Locations Brake Light Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 272 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 4996 1. INSTALL SHIFT SOLENOID VALVE S3 (a) Install the shift solenoid valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. INSTALL SHIFT SOLENOID VALVE S2 3. INSTALL SHIFT SOLENOID VALVE S4 (a) Install the shift solenoid valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 4. INSTALL SHIFT SOLENOID VALVE S1 (a) Install the shift solenoid valve and valve body wire harness clamp with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 5. INSTALL SHIFT SOLENOID VALVE SR Page 3546 NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal Main Body ECU Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Main Body ECU Communication Stop Mode - Main Body ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. Page 7008 J/B No.6 Assembly Inner Circuit Inspection Variable Valve Timing Actuator: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the camshaft timing oil control valve assembly. (c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and check the movement of the valve. OK: (d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC may be output. Page 1814 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 7578 Blower Motor: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 90 (h) If the result is not as specified, the seat heater control may have a malfunction. 2. INSPECT SEAT HEATER CONTROL SUB-ASSEMBLY RH (a) Disconnect the Y8 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) If the result is not as specified, there may be a malfunction on the wire harness side. (d) Measure the voltage according to the value(s) in the table below. Standard voltage: (e) If the result is not as specified, there may be a malfunction on the wire harness side. (f) Connect the Y8 connector. (g) Measure the voltage according to the value(s) in the table below. Standard voltage: 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) Locations Tilt Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Page 6942 J/B No.5 - Instrument Panel Center Page 6925 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 7348 Removal SUSPENSION: REAR LEAF SPRING: REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 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 SPARE TIRE Page 8363 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 1331 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 1620 Heated Glass Element Switch: Locations Window Defogger System WINDSHIELD / WINDOWGLASS: WINDOW DEFOGGER SYSTEM: PARTS LOCATION Disassembly Parking Brake Warning Switch: Service and Repair Disassembly PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and switch. Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 8115 (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 2567 (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation 6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 939 Evaporator Temperature Sensor / Switch: Service and Repair Reassembly AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: REASSEMBLY 1. INSTALL NO. 1 COOLER THERMISTOR NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted. (a) Install the sensor to a location that is 1 fin to the right or left of its previous location. 2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (a) Install the evaporator to the blower case (front side). (b) Install the blower case (back side). Page 2306 (c) Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration. NOTICE: Uniformly loosen the bolts while keeping the camshaft level. (d) Remove the 6 bearing caps. HINT Arrange the removed parts in the correct order. (e) Remove the No. 3 and No. 4 camshafts. 9. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH (a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. HINT Tape the screwdriver tip before use. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. Installation 1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): INSTALLATION 1. INSTALL CAMSHAFT BEARING CAP LH (a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. (b) Install the No. 3 and No. 4 camshafts to the camshaft housing. (c) Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions. (d) Temporarily install the 10 bolts in the order shown in the illustration. Page 7058 Standard caster inclination (unloaded vehicle): for Double Cab of Long Deck Page 2085 Engine Room R/B, J/B - Engine Compartment Left Page 5766 Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (b) Connect the No. 3 parking brake cable to the intermediate lever and install the 5 bolts. for bolt A - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) for bolt B - Torque : 14 Nm (138 kgf-cm, 10 ft-lbf) NOTICE: Do not bend and twist the parking brake cable. 4. INSTALL PARKING BRAKE SHOE LEVER LH See: Service and Repair/Reassembly 5. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Service and Repair/Reassembly 6. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Service and Repair/Reassembly 7. INSTALL PARKING BRAKE SHOE RETURN SPRING LH See: Service and Repair/Reassembly 8. CHECK PARKING BRAKE INSTALLATION See: Service and Repair/Reassembly 9. INSTALL REAR DISC LH See: Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Installation 10. ADJUST PARKING BRAKE SHOE CLEARANCE See: Adjustments 11. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Service and Repair/Reassembly 12. INSTALL REAR WHEEL LH See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Installation 13. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY Page 7763 2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Install the instrument panel reinforcement. (1) Temporarily install the instrument panel reinforcement. (2) for Passenger Side: Using a 12 mm hexagon wrench, install the 2 collars. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) (3) for Passenger Side: Using a T40 "TORX" socket, install the 2 "TORX" bolts. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) Page 5726 (b) Using a union nut wrench, connect the flexible hose to the brake tube and wheel cylinder tube while holding the flexible hose with a wrench. without union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf) with union nut wrench - Torque : 14 Nm (145 kgf-cm, 10 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). * This torque value is effective when union nut wrench is parallel to the torque wrench. NOTICE: * Do not bend or damage the brake tube and wheel cylinder tube. * Do not allow any foreign matter such as dirt and dust to enter the brake tube and wheel cylinder tube from the connecting points. 2. BLEED BRAKE LINE See: Brake Bleeding/Service and Repair/Bleeding 3. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Page 6244 Page 3544 Result E -- REPAIR OR REPLACE HARNESS OR CONNECTOR D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal A -- REPLACE ECM Power Steering ECU Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Power Steering ECU Communication Stop Mode - Power Steering ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 8588 Parking Assist Switch: Service and Repair Installation PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSTALLATION 1. INSTALL DRIVE MONITOR SWITCH (a) Attach the 2 claws to install the monitor switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 8657 Page 3566 14. CHECK BUS BUFFER ECU HINT For vehicles with a bus buffer ECU only. (a) Disconnect the J59 ECU connector. (b) Measure the resistance according to the value(s) in the table below. 15. CHECK FRONT POWER SEAT CONTROL ECU AND SWITCH LH HINT For vehicles with a front power seat control system (w/ Seat Memory) only. (a) Disconnect the Z9 and Z10 ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Page 5185 4. DISCONNECT FRONT SPEED SENSOR LH (a) Disconnect the front speed sensor LH See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Speed Sensor/Removal. 5. REMOVE FRONT AXLE HUB GREASE CAP See: Wheel Hub/Service and Repair/Removal and Replacement/Removal 6. REMOVE AXLE HUB NUT See: Wheel Hub/Service and Repair/Removal and Replacement/Removal 7. REMOVE TIE ROD END SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Removal and Replacement/Removal 8. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Steering and Suspension/Suspension/Control Arm/Service and Repair/Removal and Replacement/Front Lower Suspension Arm/Removal 9. DISCONNECT FRONT DRIVE SHAFT ASSEMBLY LH (a) Using plastic-faced hammer, disconnect the drive shaft from the axle hub side. (b) Push the steering knuckle outward and disconnect the drive shaft from the steering knuckle. 10. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Using SST, remove the drive shaft. SST : 09520-01010 SST : 09520-24010 09520-32040 NOTICE: Be careful not to damage the dust cover and oil seal. (b) Using a screwdriver, remove the snap ring from the inboard joint shaft. Installation DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for Front Differential Side) Page 3781 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Page 7289 09613-22011 15. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL (a) Using SST and a press, remove the cylinder tube oil seal. SST : 09950-60010 09951-00320 SST : 09950-70010 09951-07360 16. REMOVE RACK STEERING PISTON RING (a) Using a screwdriver, remove the piston ring and O-ring. NOTICE: Be careful not to damage the groove for the piston ring. Reassembly POWER STEERING: STEERING GEAR: REASSEMBLY NOTICE: When installing, coat the parts indicated by the arrows with power steering fluid See: Removal and Replacement/Components 1. INSTALL RACK STEERING PISTON RING (a) Coat a new O-ring with power steering fluid and install it onto the power steering rack. (b) Expand a new piston ring with your fingers. NOTICE: Be careful not to over expand the rack steering piston ring. Locations Actuator: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 5058 SST : 09950-60020 09951-00680 SST : 09950-70010 09951-07150 (b) Using SST and a press, press out the outer race and plate washer from the differential carrier. SST : 09950-60020 09951-00680 SST : 09950-70010 09951-07150 19. REMOVE DIFFERENTIAL RING GEAR (a) Place matchmarks on the ring gear and differential case. (b) Remove the 12 bolts. (c) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case. 20. REMOVE FRONT DIFFERENTIAL CASE BEARING (a) Using SST, remove the 2 bearings (inner race). Page 22 Alarm Module: Service and Repair Removal THEFT DETERRENT: THEFT WARNING ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE GLASS BREAKAGE SENSOR ECU Page 3293 ^ 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 2079 Page 7325 If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Disassembly SUSPENSION: FRONT UPPER SUSPENSION ARM: DISASSEMBLY 1. REMOVE FRONT SUSPENSION UPPER ARM BUSH (a) Using a hammer and chisel, strike and bend the entire flange of the upper arm bush as shown in the illustration. (b) Using SST and a press, press out the bush. SST : 09613-26010 SST : 09710-22021 09710-01031 SST : 09950-00020 2. REMOVE FRONT UPPER BALL JOINT DUST COVER LH (a) Using a snap ring expander, remove the dust cover set ring. Reassembly SUSPENSION: FRONT UPPER SUSPENSION ARM: REASSEMBLY 1. INSTALL FRONT UPPER BALL JOINT DUST COVER LH Page 4101 Positive Crankcase Ventilation Valve: Service and Repair Installation 1UR-FE EMISSION CONTROL: PCV VALVE: INSTALLATION 1. INSTALL PCV VALVE SUB-ASSEMBLY (a) Apply a light coat of engine oil to the O-ring. HINT * When reusing the PCV valve, inspect the O-ring. * If the O-ring has scratches or cuts, replace the PCV valve. (b) Install the PCV valve. Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf) 2. CONNECT PCV VALVE HOSE 3. INSTALL NO. 3 ENGINE COVER (a) Install the No. 3 engine cover. 4. INSTALL NO. 4 ENGINE COVER (a) Install the No. 4 engine cover. 5. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Body - Tube Step Step Pad Lifting/Cracking Auxiliary Step / Running Board: Customer Interest Body - Tube Step Step Pad Lifting/Cracking T-SB-0164-10 June 28, 2010 Tube Step - Step Pad Lifting/Cracked Service Category Vehicle Exterior Section Exterior Panels/Trim Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a condition where the step pad has lifted or cracked. To improve the serviceability of the tube step the step pad is now available as a separate service part. Follow the procedure in this bulletin to replace the step pad. Removal of the tube step is not required to perform step pad replacement. Parts Information Warranty Information APPLICABLE WARRANTY ^ Toyota accessories installed as original equipment are 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. ^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months, regardless of mileage, from the date of installation on the vehicle, or the remainder of the applicable New Vehicle Limited Warranty, whichever provides the greater coverage. ^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of purchase. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Repair Procedure Page 6821 Page 6973 Push the terminal retainer down to the temporary lock position. Page 6105 Starter Motor: Testing and Inspection Starter (for 2.0 Kw Type) 1UR-FE STARTING: STARTER (for 2.0 kW Type): INSPECTION 1. INSPECT STARTER ASSEMBLY CAUTION: As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may became hot and cause injury. NOTICE: The following tests must be performed within 3 to 5 to prevent the coil from burning out. (a) Perform a pull-in test. (1) Disconnect the field coil wire from terminal C. (2) Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear moves outward. If the clutch pinion gear does not move outward, replace the magnet starter switch assembly. (b) Perform a holding test. (1) Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the magnet starter switch assembly. (c) Inspect clutch pinion gear return. (1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward. If the clutch pinion gear does not move inward, replace the magnet starter switch assembly. Page 3178 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Page 5680 Brake Bleeding: Service and Repair Replacement BRAKE: BRAKE FLUID: REPLACEMENT NOTICE: * Perform fluid replacement with the parking brake applied. * Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir. * Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off immediately. * Add fluid to the brake fluid reservoir as necessary so that the fluid does not decrease below the MIN level. 1. REPLACE BRAKE FLUID (a) Replace the brake fluid. (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (7) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. (10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (13)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (b) Check and bleed brake system. (1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform the following air bleed procedures. * Low pedal or spongy pedal. * Brake pedal is depressed firmly but braking is insufficient. (c) Inspect for the brake fluid leak. (d) Check and adjust brake fluid level in reservoir See: Hydraulic System/Brake Fluid/Testing and Inspection. Page 9134 Trailer Towing Part 2 Tools and Equipment Fuel Supply Line: Tools and Equipment Niss./Toy. Line Disconnect Tool AST tool# 8026 5/16"Fuel Line Disconnect Tool. Used for disconnecting the fuel line from the fuel rail. Applicable to 2004 and newer Nissan and Toyota Models - 5/16" Fuel Line Disconnect Tool - Quick Line Removal*Green-Anodized Aluminum Construction - See Application Chart - Included in the #8110 Line Disconnect Set. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Page 9020 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Components Variable Valve Timing Actuator Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS Page 8529 11. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 7217 Steering Column Control Module: Service and Repair Installation STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): INSTALLATION 1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU (a) Install the ECU with the 2 screws. Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Installation 6. INSTALL LOWER STEERING COLUMN COVER (a) Attach the 2 claws to install the steering column lower cover. 7. INSTALL UPPER STEERING COLUMN COVER Page 1356 Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 2165 Tire Pressure Warning Reset Switch: Testing and Inspection TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION 1. CHECK TIRE PRESSURE WARNING RESET SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 1676 for Double Cab of Long Deck for CrewMax of standard deck Page 7975 Components Traction Control Switch: Service and Repair Components BRAKE CONTROL: VSC OFF SWITCH: COMPONENTS Page 5428 Control Module: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE 4WD CONTROL ECU (a) Disconnect the 2 ECU connectors. (b) Remove the bolt and ECU. Page 1311 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Engine Controls - ECM Update For Shift Performance PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 4930 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 7. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 8. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 9. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 10. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 11. REMOVE LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 12. REMOVE UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 13. REMOVE FRONT SEAT ASSEMBLY LH (a) for Manual Seat Type: Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. (b) for Power Seat Type: Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. (c) for Center Seat: Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal. (d) for Fold Down Seat: Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Removal. 14. REMOVE COLUMN SHIFT TRANSMISSION CONTROL CABLE ASSEMBLY Page 6825 Page 5278 (2) Subtract the angle of the transfer flange (A) measured before installing the propeller shaft from the angle of the intermediate shaft (C) to calculate the No. 1 joint angle. No. 1 joint angle: Angle of intermediate shaft (C) - Angle of transfer flange (A) Measured Value (Reference): HINT * Using the following chart, check if the calculated No. 1 joint angle is within the specified value. * The tolerance is +/-0°60' (1.00°). Standard No. 1 joint angle: Page 3466 B -- GO TO CAN MAIN WIRE FOR DISCONNECTION See: Symptom Related Diagnostic Procedures/CAN Communication System/Open In CAN Main Wire C -- GO TO CHECK CAN BUS LINES FOR SHORT CIRCUIT See: Symptom Related Diagnostic Procedures/CAN Communication System/Short in CAN Bus Lines A -- Continue to next step. 6. CHECK V BUS CIRCUIT +B (CANH, CANL - BAT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO +B See: Symptom Related Diagnostic Procedures/CAN Communication System/Short to B+ in CAN Bus Line OK -- Continue to next step. 7. CHECK V BUS CIRCUIT GND (CANH, CANL - CG) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO GND See: Symptom Related Diagnostic Procedures/CAN Communication System/Short to GND in CAN Bus Line OK -- Continue to next step. 8. CHECK ECUS CONNECTED TO CAN BUS (USING TECHSTREAM)* (a) Select "CAN Bus Check" from the "System Select". Windshield Deicer System Heated Glass Element Relay: Locations Windshield Deicer System WINDSHIELD / WINDOWGLASS: WINDSHIELD DEICER SYSTEM: PARTS LOCATION Page 3390 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 9293 Service and Repair Fuel Pressure Release: Service and Repair 1UR-FE FUEL: FUEL SYSTEM: PRECAUTION CAUTION: * Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. * Do not smoke or be near an open flame when working on the fuel system. * Keep gasoline away from rubber and leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures. (1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. (2) Put a container under the connecting part of the pressure line. (3) Slowly loosen the connection. (4) Disconnect the connection. (5) Plug the connection with a rubber plug. (b) Observe these precautions when removing and installing the injectors: Components Four Wheel Drive Selector Switch: Service and Repair Components JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS Page 918 Cabin Temperature Sensor / Switch: Service and Repair Installation AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): INSTALLATION 1. INSTALL ROOM TEMPERATURE SENSOR (a) Attach the 2 claws to install the sensor. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 3. INSTALL INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 5. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Body - Bumper Component Repair Front Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: BUMPER COMPONENT REPAIR SECTION: EXTERIOR BULLETIN # 172 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2009 While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinforcements there is no way to certify that a repaired part will function as originally intended under all future operating conditions and subsequent collisions. Original Equipment bumper components comply with Federal Motor Vehicle Safety Standards established under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is recommended to replace damaged bumper impact energy absorbers and reinforcements with genuine new original equipment replacement parts only. For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair & Refinish Training. Visit www.crrtraining.com for training information. Page 709 Power Seat Switch: Testing and Inspection Front Power Seat Lumbar Switch (for Power Seat) SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): INSPECTION 1. INSPECT FRONT POWER SEAT LUMBAR SWITCH LH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. 2. INSPECT FRONT POWER SEAT LUMBAR SWITCH RH Page 8616 1. Please compare customer's iPod(TM) with the compatible models table listed below. If the customers' iPod(TM) is NOT listed, this TSB does NOT apply. 2. Verify the condition. NOTE If USB device error occurs during every use, visually inspect the port. 3. Verify the error condition continues when using a known good USB cable. 4. Replace the Multi-Media Interface ECU by following procedures in the Repair Manual. Page 52 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL 1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE FRONT DOOR SCUFF PLATE RH Page 9238 Page 4043 (b) Disconnect the 6 air pump insulators. Page 5293 SST : 09955-04100 HINT Make sure the claws of SST are securely attached to the universal joint yoke. (h) Clamp the protruding universal joint spider bearing in a vise. (i) Using a brass bar and hammer, tap the universal joint yoke to remove the universal joint spider bearing. NOTICE: Do not tap the intermediate shaft tube. HINT Use the same removal procedure for the universal joint spider bearing on the opposite side. (j) Disconnect the intermediate shaft from the propeller shaft. (k) Using SST, pull out the universal joint spider bearing from the propeller shaft yoke. SST : 09331-60010 SST : 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09957-04010 09958-04011 Page 8210 Seat Belt: Testing and Inspection Front Seat Inner Belt Assembly SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: INSPECTION 1. INSPECT FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: * If the result is not as specified, replace the inner belt assembly. Front Seat Outer Belt Assembly (for Center Seat) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): INSPECTION 1. INSPECT CENTER FRONT SEAT BELT ASSEMBLY RH CAUTION: Do not disassemble the retractor. (a) Before installing the seat belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) Check the fastening function of the child restraint system. NOTICE: Page 1636 Power Window Switch: Testing and Inspection Front Passenger Side Power Window Switch WINDSHIELD / WINDOWGLASS: FRONT PASSENGER SIDE POWER WINDOW SWITCH: INSPECTION 1. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/o Jam Protection Function) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: * If the result is not as specified, replace the power window regulator switch. 2. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/ Jam Protection Function) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 3442 NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step. 6. CONNECT CONNECTOR (a) Reconnect the J94 No. 1 junction connector connector. (b) Reconnect the J113 No. 2 junction connector connector. NEXT -- Continue to next step. 7. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU) (a) Disconnect the J84 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU) OK -Continue to next step. 8. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - MAIN BODY ECU) (a) Disconnect the J96 No. 1 junction connector connector. Airbag System Air Bag Deactivation Switch: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 1061 Removal LIGHTING: FRONT DOOR COURTESY SWITCH: REMOVAL HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT DOOR COURTESY SWITCH (a) Remove the bolt. Page 5831 Traction Control Relay: Testing and Inspection BRAKE CONTROL: STOP LIGHT CONTROL RELAY: ON-VEHICLE INSPECTION 1. CHECK STOP LIGHT CONTROL RELAY (a) Remove the stop light control relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) If the result is not as specified, replace the relay. (d) Install the stop light control relay. Page 2340 Engine Controls - ECM Update For Shift Performance PROM - Programmable Read Only Memory: Customer Interest Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Oil Pressure Sender Oil Pressure Sender: Diagrams Oil Pressure Sender Page 8218 SST : 09082-00700 SST : 09082-00770 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Move SST at least 10 m (32.8 ft.) away from the front of the vehicle. (4) Close all the doors and windows of the vehicle. HINT Leave a gap in one of the windows for inserting SST wire harness. NOTICE: Take care not to damage SST wire harness. (5) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the negative (-) terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (32.8 ft.) of the vehicle. (2) Press SST activation switch to activate the seat belt pretensioner. HINT The seat belt pretensioner operates at the same time SST activation switch's LED illuminates. (f) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: * Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. * Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. HINT When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated front seat outer belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) CAUTION: Be sure to follow the procedures listed below when activating the seat belt pretensioner. (a) Remove the front seat outer belt. Page 3268 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 1474 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 1150 Camshaft Position Sensor: Diagrams A/C Amplifier, A/C Blower Assembly Control Module HVAC: Diagrams A/C Amplifier, A/C Blower Assembly Page 5049 21. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Install the drive pinion, front bearing (inner race) and oil slinger. (b) Using SST and the companion flange, install the bearing (inner race) and then remove the companion flange. SST : 09950-30012 09951-03010 09953-03010 09954-03010 09956-03050 SST : 09955-03050 22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end. SST : 09316-12010 SST : 09649-17010 Standard oil seal depth: Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 5920 1. INSTALL SKID CONTROL SENSOR WIRE (a) Install the sensor clamp with the nut (labeled A). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Make sure the clamp's rotation stopper touches the installation position. (b) Install the sensor clamp with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: When installing the clamp, do not twist the wire harness. (c) Attach the 7 clips (labeled C). NOTICE: * When installing the clamps, do not twist the wire harness. * When installing the clamps, securely insert them as shown in the illustration. (d) Connect the sensor connector (labeled D). NOTICE: Securely connect the connector. 2. INSTALL REAR SPEED SENSOR LH (a) Install the speed sensor (labeled A) with the nut (labeled B). Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Connect the speed sensor connector (labeled C). NOTICE: Securely connect the connector. 3. INSTALL REAR SPEED SENSOR RH (a) Install the speed sensor (labeled A) with the nut (labeled B). Page 8786 Speaker: Testing and Inspection Floor Speaker (for CrewMax) AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSPECTION 1. INSPECT NO. 1 BOX SPEAKER ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Floor Speaker (for Double Cab) AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSPECTION 1. INSPECT BOX SPEAKER ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Front Door Speaker (for CrewMax) AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSPECTION 1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard) Page 959 Solar Sensor: Testing and Inspection AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSPECTION 1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Connect the battery's positive (+) lead to terminal 6 and the negative (-) lead to terminal 3, then measure the voltage according to the value(s) in the table below. Standard voltage: NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. HINT * As the inspection light is moved away from the sensor, the voltage decreases. * Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. (b) If the result is not as specified, replace the solar sensor. Up to 11/2009 Traction Control Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 2690 Water Pump: Testing and Inspection 1UR-FE COOLING: WATER PUMP: ON-VEHICLE INSPECTION 1. INSPECT WATER PUMP ASSEMBLY (a) Visually check the air hole and drain hole for coolant leakage. (b) If leakage is found, replace the water pump assembly. (c) Turn the pulley and check that the water pump bearing moves smoothly and quietly. (d) If necessary, replace the water pump assembly. Page 4166 Air Conditioning System (for Automatic Air Conditioning System) Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 7476 Tire Pressure Module: Diagrams Page 60 Parking Assist Control Module: Service and Repair Removal PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE CLEARANCE WARNING ECU WITH BRACKET (a) Disconnect the ECU connectors and detach the harness clamp. NOTICE: Do not apply excessive force to the wire harnesses. (b) Remove the bolt, nut and ECU with bracket. 8. REMOVE CLEARANCE WARNING ECU ASSEMBLY (a) Remove the 2 nuts and clearance warning ECU from the bracket. NOTICE: * Avoid any impact to the clearance warning ECU. * Do not drop the ECU. If it is dropped, replace it with a new one. Page 2096 Engine Room R/B And Engine Room J/B Inner Circuit Page 8764 Remote Switch: Service and Repair Removal AUDIO / VISUAL: STEERING PAD SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD SWITCH ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws. (c) Detach the 4 pins and remove the steering pad switch. Page 7150 Tire Pressure Sensor: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL 1. REMOVE TIRE 2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Remove the valve core and cap, and release the air from the tire. (b) After ensuring that a sufficient amount of air has been released, remove the nut and washer that is used to secure the tire pressure warning valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire. HINT Keep the removed cap, valve core, nut and washer. (c) Disengage the bead using the shoe of a tire remover. NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due to interference between the sensor and tire bead. (d) Remove the bead on the upper side. (e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on the lower side. HINT * The grommet is a non-reusable part. * Check that there are no cracks or damage on the grommet. If any damage is found, replace the washer and nut. Page 8358 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Page 7561 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSPECTION 1. INSPECT AMBIENT TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NOTICE: * Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. * When measuring the resistance, the sensor temperature must be the same as the ambient temperature. HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the ambient temperature sensor. Page 7638 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 6195 Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Page 6399 Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Pump: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 3448 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU WITH ACTUATOR (CANH, CANL) OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal 16. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR) (a) Disconnect the J6 steering angle sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE SENSOR (CANH, CANL) OK -- REPLACE STEERING ANGLE SENSOR 17. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU) (a) Disconnect the J101 power steering ECU connector. Page 9071 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 1890 Page 1284 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 1714 Standard caster inclination (unloaded vehicle): for Double Cab of Long Deck Page 8952 HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 14. REMOVE NO. 2 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the rear bumper. Installation PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): INSTALLATION 1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the rear bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 2. INSTALL NO. 1 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. Components Engine Control Module: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS Page 3857 Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch Page 5482 Actuator: Service and Repair Installation DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): INSTALLATION 1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator. (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the differential tube as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent HINT Install the actuator within 10 minutes of applying seal packing. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the actuator onto the differential tube. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (g) Install the 4 bolts. Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) (h) Connect the actuator hose. (i) Connect the actuator connector. 2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and Inspection/Component Tests and General Diagnostics/Touch Select 2-4 and High-Low System. Page 4069 Evaporative Emission Control Canister: Service and Repair Installation 1UR-FE EMISSION CONTROL: CANISTER: INSTALLATION 1. INSTALL CANISTER ASSEMBLY (a) Install the canister with the 4 bolts. Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) (b) Connect the wire harness clamp. (c) Connect the vent line hose. (1) Push the hose into the port and push the retainer to lock it. NOTICE: * Check for damage or foreign objects on the connected part. * After connecting, check that the vent hose and the valve are securely connected by pulling on them. (d) Connect the air inlet line hose. NOTICE: * Check for damage or foreign objects on the connected part. * After connecting, check that the vent hose and the valve are securely connected by pulling on them. (e) Connect the purge line hose. Page 144 (a) for Manual Air Conditioning System: Disconnect the 2 connectors. (b) for Automatic Air Conditioning System: Disconnect the 3 connectors. (c) Remove the 2 screws and amplifier. Page 2853 Fuel Pump Control Unit: Locations Crew Max Body Page 6762 JQ1-LJ1 Page 3528 NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - ECM)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (4WD CONTROL ECU) OK -- Continue to next step. 22. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - ECM) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (ECM) OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR 23. CHECK FOR SHORT TO GND IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) (a) Disconnect the J19 air conditioning amplifier connector. Page 2990 Throttle Position Sensor: Diagrams Locations Shift Solenoid: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1722 8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: * Some systems need to be initialized after the cable is reconnected ( See: Testing and Inspection/Programming and Relearning). * After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 10. PERFORM YAW RATE AND DECELERATION SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate and deceleration sensor zero point calibration See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning. 11. CHECK STEERING ANGLE SENSOR ZERO POINT CALIBRATION Page 5741 Hydraulic Control Assembly - Antilock Brakes: Overhaul Disassembly BRAKE CONTROL: BRAKE ACTUATOR: DISASSEMBLY 1. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (a) Using a T30 "TORX" wrench, remove the 3 screws and actuator bracket. Reassembly BRAKE CONTROL: BRAKE ACTUATOR: REASSEMBLY 1. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (a) Using a T30 "TORX" wrench, install the actuator bracket with the 3 screws. Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf) Page 3473 HINT * o: DTC is memorized. * *1: Only during failure status. Page 6071 Ignition Switch: Service and Repair Removal 1UR-FE STARTING: IGNITION SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal. (b) for Manual Tilt and Manual Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal. (c) for Power Tilt and Power Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal. 3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Disassembly 4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly 5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly 6. REMOVE IGNITION SWITCH ASSEMBLY (a) Detach the 2 claws and remove the ignition switch from the steering lock. Locations Engine Temperature Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 387 Engine Control Module: Pinout Values and Diagnostic Parameters 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM 1. CHECK ECM (a) Measure the voltage according to the value(s) in the table below. HINT The standard voltage between each pair of ECM terminals is shown in the table below. The appropriate conditions for checking each pair of terminals are also indicated. The result of checks should be compared with the standard voltage for that pair of terminals, displayed in the Specified Condition column. The illustration above can be used as a reference to identify the ECM terminal locations. Page 6151 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 621 Remote Switch: Locations Navigation System (w/ USB Audio System) NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION Page 7383 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 6466 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Components Clockspring Assembly / Spiral Cable: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: COMPONENTS Page 3294 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 1285 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 3422 Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (STEERING ANGLE SENSOR) OK -- REPLACE STEERING ANGLE SENSOR 8. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU) NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR)". (a) Disconnect the J59 bus buffer ECU connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR) A -- Continue to next step. 9. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Page 2836 Engine Control Module: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION 1. INSTALL GASKET (a) Clean the ECM seal's surface with non-residue solvent. (b) Attach a new gasket to the ECM. 2. INSTALL ECM (a) Install the ECM with the 4 bolts. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) NOTICE: * Make sure the gasket is not folded or caught on any area on the surrounding part. * Make sure there is no foreign matter caught between the gasket and surrounding part. * Do not damage the gasket. (b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors. NOTICE: * Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do this may cause the lock lever and terminals to break. * Do not twist the wire harness when connecting the ECM connectors. (c) Connect the wire harness clamp. 3. CONNECT CONNECTOR HOLDER BLOCK (a) Connect the connector holder block with the 3 bolts. Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf) Page 7309 Ball Joint: Testing and Inspection Front Upper Suspension Arm SUSPENSION: FRONT UPPER SUSPENSION ARM: INSPECTION 1. INSPECT FRONT SUSPENSION UPPER ARM ASSEMBLY LH (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 at a rate of 3 to 5 seconds per 1 turn and take the torque reading on the fifth turn. Standard turning torque: 0.98 to 4.41 N*m (1.0 to 45 kgf*cm, 9 to 39 in.*lbf) Page 5869 Parking Brake Warning Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6470 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 1453 Diagrams Variable Valve Timing Actuator Position Sensor: Diagrams Page 3994 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 7632 Compressor HVAC: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 7991 (a) Disconnect the 3 airbag wire harness clamps from under the seat. (b) Remove the 4 bolts and seatback. 11. REMOVE FRONT SEATBACK BOARD See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 12. REMOVE FRONT SEATBACK LOCK SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 13. REMOVE FRONT SEATBACK LOCK SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 14. REMOVE FRONT SEATBACK COVER WITH PAD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 15. REMOVE FRONT SEAT SIDE AIRBAG ASSEMBLY (a) Disconnect the clamp. (b) Remove the 2 nuts and the front seat side airbag assembly. CAUTION: * The nuts must not be reused. * Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold Down Seat Type): INSTALLATION Page 719 Power Seat Switch: Service and Repair Front Power Seat Lumbar Switch (for Power Seat) Components SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): COMPONENTS Page 7715 Control Module HVAC: Diagrams A/C Amplifier Page 3529 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING AMPLIFIER (CANH, CANL) OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY 24. CHECK FOR SHORT TO GND IN CAN BUS WIRE (BUS BUFFER ECU) (a) Disconnect the J59 bus buffer ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+, CAN-) OK -- REPLACE BUS BUFFER ECU 25. CHECK FOR SHORT TO GND IN CAN BUS WIRE (4WD CONTROL ECU) (a) Disconnect the A25 4WD control ECU connector. Page 8673 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 5089 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 7534 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 8015 Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 8225 (d) Activate the seat belt pretensioner. (1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. (2) Check that no one is within 10 m (32.8 ft.) of the wheel. (3) Press SST activation switch to activate the seat belt pretensioner. HINT The seat belt pretensioner operates at the same time SST activation switch's LED illuminates. (e) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: * Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. * Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. (1) Remove the tire (with wheel) and SST. (2) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. Front Seat Outer Belt Assembly (for Regular Cab) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): DISPOSAL HINT When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in accordance with the procedures described below. If any abnormality occurs during activation of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a front seat outer belt that has a non-activated pretensioner. * The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to nearby people. * When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (32.8 ft.) away from the front seat outer belt. * Use gloves and safety glasses when handling a front seat outer belt with an activated pretensioner. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. * Perform procedures in a place away from electrical interference. * When activating the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). 1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Page 7923 (b) With the lower No. 2 instrument panel airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the lower No. 2 instrument panel airbag with a new one: * Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag. * Cracks or other damage to the connector. * Deformation or cracks on the instrument panel reinforcement. CAUTION: For removal and installation procedures of the lower No. 2 instrument panel airbag, be sure to follow the correct procedure. Curtain Shield Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: ON-VEHICLE INSPECTION 1. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the curtain shield airbag installed on the vehicle, perform a visual check. If any of the defects mentioned below are present, replace the curtain shield airbag with a new one: Cuts, minute cracks or marked discoloration on the curtain shield airbag. 2. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the curtain shield airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the curtain shield airbag with a new one: * Cuts, minute cracks or marked discoloration on the curtain shield airbag. * Cracks or other damage to the connectors. CAUTION: For removal and installation procedures of the curtain shield airbag, be sure to follow the correct procedure. Curtain Shield Airbag Assembly (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax): ON-VEHICLE INSPECTION 1. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 5956 Push the terminal retainer down to the temporary lock position. Page 1576 Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch Page 6364 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 3073 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 6279 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 3433 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU (CANH, CANL) OK -- REPLACE COMBINATION METER ASSEMBLY 14. CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU) (a) Disconnect the J2 main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH, CANL) OK -- REPLACE MAIN BODY ECU 15. CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A17 skid control ECU with actuator connector. Page 7063 Standard steering axis inclination (unloaded vehicle): for CrewMax of standard deck Page 3456 Standard resistance: NG -- REPAIR OR REPLACE BUS BUFFER ECU BRANCH WIRE OR CONNECTOR (CAN+, CAN-) OK -- REPLACE BUS BUFFER ECU Center Airbag Sensor Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Center Airbag Sensor Communication Stop Mode - Center Airbag Sensor Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Page 8645 2. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 3. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 4. INSTALL CENTER SEAT BACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 7752 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 6980 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Testing and Inspection Parking Assist Switch: Testing and Inspection PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSPECTION 1. INSPECT DRIVE MONITOR SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the monitor switch. (c) Inspect the switch illumination. (1) Connect the positive (+) lead of the battery to terminal 1 (ILL+) and the negative (-) lead to terminal 6 (ILL-). (2) Check that the LED comes on. OK: LED comes on. (3) If the result is not as specified, replace the monitor switch. Page 1812 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 6258 Page 4470 Throttle Position Sensor: Diagrams Page 1429 Page 8670 Push the terminal retainer down to the temporary lock position. Page 7323 (a) Using a chisel and hammer, pry the flange of the bush outward. (b) Using SST, remove the bush. SST : 09950-40011 09951-04010 09952-04010 09953-04020 09954-04020 09955-04011 09957-04010 09958-04011 SST : 09950-60010 09951-00650 3. REMOVE FRONT NO. 1 SPRING BUMPER LH (a) Remove the No. 1 spring bumper from the vehicle. Reassembly SUSPENSION: FRONT LOWER SUSPENSION ARM: REASSEMBLY 1. INSTALL FRONT NO. 1 SPRING BUMPER LH (a) Install the No. 1 spring bumper to the vehicle. Torque : 31 Nm (316 kgf-cm, 23 ft-lbf) Page 3530 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU (CANH, CANL) OK -- REPLACE 4WD CONTROL ECU 26. CHECK FOR SHORT TO GND IN CAN BUS WIRE (ECM) (a) Disconnect the A24 ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Result E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL) D -- REPLACE ECM Page 6406 Tailgate Wire Front Seat Wire Page 3248 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 3365 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 7001 Junction Connector (CAN No.2) - Lower Finish Panel Page 717 (a) Disconnect the switch connector. (b) Remove the 3 screws and switch. Installation SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT POWER SEAT SWITCH LH (a) Install the switch with the 3 screws. (b) Connect the switch connector. 2. INSTALL LEG SUPPORT ADJUSTMENT SWITCH (w/ Leg Support Adjustment Switch) (a) Connect the switch connector. (b) Install the switch with the 2 screws. (c) Attach the 2 wire harness clamps. 3. INSTALL FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 4. INSTALL RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 5. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 6. INSTALL FRONT SEAT ASSEMBLY LH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Page 1860 Step 4. Remove the cover by sliding up while pulling toward you Step 5. Remove the filter cover. Page 7236 Power Steering Pressure Switch: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: REMOVAL 1. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DRAIN POWER STEERING FLUID 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the power steering oil pressure switch connector. (b) Remove the power steering oil pressure switch. (c) Remove the O-ring. Page 999 Fuel Gauge Sender: Testing and Inspection 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSPECTION 1. INSPECT FUEL SENDER GAUGE ASSEMBLY (a) Check that the float moves smoothly between F and E. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the fuel sender gauge assembly. Page 7601 Page 5149 Page 5990 Neutral Safety Switch: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL 1. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut and disconnect the cable. 2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Disconnect the switch connector. (b) Remove the nut, spring washer and transmission control shaft lever RH. (c) Using a screwdriver, bend the tabs of the lock washer. (d) Remove the lock nut and lock washer. (e) Remove the bolt and switch. Page 8075 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BATTERY (a) Disconnect the cable from the positive (+) battery terminal. (b) Loosen the nut, move the stay off the battery, and remove the battery. 3. REMOVE FRONT AIRBAG SENSOR (a) Remove the nut and front airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Connect the connector. (d) Install the front airbag sensor with the nut. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) Page 8360 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 4345 Page 1470 Page 6343 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 3924 Variable Valve Timing Actuator Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE VVT SENSOR (a) Disconnect the 4 sensor connectors. (b) Remove the 4 bolts and 4 sensors. Page 4195 Recall - Floor Mat/Accelerator Pedal Interferance Technical Service Bulletin # SSC90L Date: 091001 Page 9118 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 8617 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 5. Verify normal USB operation after repair. Page 1713 Standard caster inclination (unloaded vehicle): for Regular Cab of Long Deck Standard caster inclination (unloaded vehicle): for Double Cab of Standard Deck Page 3506 Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR) OK -- Continue to next step. 10. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR STEERING ANGLE SENSOR) (a) Disconnect the J87 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR) OK -Continue to next step. 11. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - POWER STEERING ECU) NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)". (a) Disconnect the J115 No. 1 junction connector connector. Page 2030 Driver Side J/B - Cowl Side Left Components Tire Pressure Monitor Receiver / Transponder: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS Page 2490 NOTICE: Do not damage the surface of the oil seal press fit hole and crankshaft. HINT Tape the screwdriver tip before use. Up to 11/2009 Traction Control Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Tire Pressure Module: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS Page 6526 "Case2" 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 182 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 7941 Wire harness: Stripped wire harness section 1.25 mm2 or more (0.00193 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2). HINT To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Position the curtain shield airbag inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) (2) Tie the curtain shield airbag to the tire with several wire harnesses. CAUTION: Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the curtain shield airbag may become loose due to the shock when the airbag is deployed. NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (e) Install SST. (1) After connecting SST each other, connect them to the curtain shield airbag. SST : 09082-00802 09082-10801 09082-40800 Page 536 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Install the receiver with the bolt. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the receiver connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 1518 (g) Hold the switch in position and tighten the bolt. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (h) Using a screwdriver, bend the tabs of the lock washer. (i) Install the transmission control shaft lever RH with the spring washer and nut. Torque : 16 Nm (160 kgf-cm, 12 ft-lbf) (j) Connect the switch connector. 2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the cable with the nut. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L bracket of the cable faces the inside of the vehicle. 3. ADJUST SHIFT LEVER POSITION (for Column Shift Type) See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type) 4. ADJUST SHIFT LEVER POSITION (for Floor Shift Type) See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type) Page 4608 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 8041 Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable, Driver Side Squib 2nd Step Circuit Page 9259 4. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Attach the 4 claws to install the control switch. 5. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH (a) Connect the connector. (b) Attach the 2 clips to install the rear upper door armrest base panel. 6. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH (a) Attach the 4 claws to install the bezel plug. Page 7924 (b) With the curtain shield airbag installed on the vehicle, perform a visual check. If any of the defects mentioned below are present, replace the curtain shield airbag with a new one: Cuts, minute cracks or marked discoloration on the curtain shield airbag. 2. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the curtain shield airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the curtain shield airbag with a new one: * Cuts, minute cracks or marked discoloration on the curtain shield airbag. * Cracks or other damage to the connectors. CAUTION: For removal and installation procedures of the curtain shield airbag, be sure to follow the correct procedure. Driver Side Knee Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY: ON-VEHICLE INSPECTION 1. CHECK LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the lower No. 1 instrument panel airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the lower No. 1 instrument panel airbag with a new one: Cuts, minute cracks or marked discoloration on the lower No. 1 instrument panel airbag. 2. CHECK LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 142 Control Module HVAC: Service and Repair Removal AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE RH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE COWL SIDE TRIM BOARD RH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) for Column Shift Type: Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE INSTRUMENT SIDE PANEL RH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Page 1187 Manifold Pressure/Vacuum Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSPECTION 1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Check the resistance. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the manifold absolute pressure sensor. Page 3624 SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Page 4918 5. INSTALL COLUMN SHIFT SHIFT LEVER SUB-ASSEMBLY (a) Apply MP grease to the 2 lever selecting bushes as shown in the illustration. (b) Install the 2 lever selecting bushes and shift lever to the column shift control shift lever retainer. (c) Pass the wire harness of the shift lever through the control shaft tube clamp. (d) Attach the control shaft tube clamp to the column shift control shift lever retainer. (e) Securely connect the 3 wire terminals to terminal 4 (SFTD-), 5 (SFTU+) and 11 (E) of the transmission control switch connector. Then push in the connector housing retainer to lock it. Page 5643 Wheel Speed Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6777 Page 6276 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 3519 NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step. 6. CONNECT CONNECTOR (a) Reconnect the J94 No. 1 junction connector connector. (b) Reconnect the J113 No. 2 junction connector connector. NEXT -- Continue to next step. 7. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU) (a) Disconnect the J84 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (COMBINATION METER ECU) OK -Continue to next step. 8. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - MAIN BODY ECU) (a) Disconnect the J96 No. 1 junction connector connector. Page 3297 ^ 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 1210 5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor connector. (b) Disconnect the air fuel ratio sensor connector. (c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support. (d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH. 7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) for 2WD: Disconnect the air fuel ratio sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION 1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 Page 6965 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 5023 Removal DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): REMOVAL 1. REMOVE REAR WHEEL 2. REMOVE PROPELLER SHAFT ASSEMBLY (a) Remove the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Removal. (b) Remove the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Removal. Page 9072 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 288 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Side Airbag Sensor Impact Sensor: Diagrams Side Airbag Sensor Page 7570 Blower Motor: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 5632 Traction Control Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 1060 Page 5567 * The zero point calibration is performed only once after the system enters test mode. * Calibration cannot be performed again until the stored data is cleared once. (2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased. (3) Turn the ignition switch OFF. 4. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING SST CHECK WIRE) (a) Turn the ignition switch to ON. (b) Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more within 8 seconds. SST : 09843-18040 (c) Check that the SLIP indicator light comes on. (d) Using a check wire, perform the zero point calibration of the deceleration sensor. 5. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND DECELERATION SENSOR (WHEN USING SST CHECK WIRE) NOTICE: * While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it stationary. (Do not start the engine.) * While obtaining the zero point, do not depress the brake pedal. * Obtain the zero point on a level surface (with an inclination of 1° or less). (a) Enter Test Mode. (1) Turn the ignition switch off. (2) Check that the shift lever is in parking or neutral and apply the parking brake. CAUTION: Application of the parking brake is not necessary for entering test mode. However, apply the parking brake for safety. (3) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3. SST : 09843-18040 (4) Turn the ignition switch to ON. NOTICE: Do not start the engine. (b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor. Page 6481 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 7972 Air Bag: Removal and Replacement Components SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax): COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Page 740 Seat Heater Switch: Service and Repair Removal SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY See: Heating and Air Conditioning/Control Assembly/Service and Repair/Air Conditioning Panel (for Floor Shift Type)/Removal 11. REMOVE SEAT HEATER SWITCH (a) w/ Seat Heater System: Detach the 4 claws and remove the 2 seat heater switches. (b) w/ Climate Control Seat System: Detach the 8 claws and remove the 2 seat heater switches. Page 6522 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 3470 The steering angle sensor is connected to the CAN communication system but CAN communication DTCs are not output. (h) CENTER AIRBAG SENSOR HINT The center airbag sensor is connected to the CAN communication system but CAN communication DTCs are not output. (i) POWER STEERING ECU For vehicles with a power steering ECU only. HINT The power steering ECU is connected to the CAN communication system but CAN communication DTCs are not output. (j) 4WD CONTROL ECU For vehicles with 4WD only. HINT The 4WD control ECU is connected to the CAN communication system but CAN communication DTCs are not output. (k) BUS BUFFER ECU For vehicles with a bus buffer ECU only. HINT The bus buffer ECU is connected to the CAN communication system but CAN communication DTCs are not output. (l) FRONT POWER SEAT CONTROL ECU AND SWITCH LH For vehicles with a front power seat control system (w/ Seat Memory) only. HINT The front power control seat ECU and switch LH is connected to the CAN communication system but CAN communication DTCs are not output. (m)OUTER MIRROR CONTROL ECU For vehicles with a front power seat control system (w/ Seat Memory) only. HINT The outer mirror control ECU and switch LH is connected to the CAN communication system but CAN communication DTCs are not output. 4. DTC COMBINATION TABLE Page 5994 5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Inspect the switch See: Testing and Inspection/Initial Inspection and Diagnostic Overview. Page 2598 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 737 (f) If the result is not as specified, replace the switch. Page 6439 Power Distribution Module: Diagrams Voltage Inverter Page 7691 Condenser HVAC: Service and Repair Installation AIR CONDITIONING: CONDENSER: INSTALLATION 1. INSTALL COOLER DRYER (a) Using pliers, install the cooler dryer. (b) Apply a sufficient amount of compressor oil to the contact surfaces of a new O-ring and the cap. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring to the cap. (d) Using a 14 mm socket hexagon wrench, install the cap to the modulator. Torque : 2.9 Nm (30 kgf-cm, 26 in-lbf) 2. INSTALL COOLER CONDENSER ASSEMBLY (a) Install the cooler condenser with the 2 bolts, as shown in the illustration. Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) Page 6981 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 2400 (a) Hook the engine under cover to the vehicle body as shown in the illustration. (b) Install the 3 screws and 5 bolts. for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf) Page 6106 (d) Perform the operation test without load. (1) Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded. Torque : 6.5 Nm (66 kgf-cm, 57 in-lbf) (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Then measure the current. Standard current: 190 A or less at 11.5 V (5) If the result is not as specified, replace the starter assembly. 2. INSPECT STARTER ARMATURE ASSEMBLY (a) Check the surface of the commutator for dirt and burns. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. (b) Inspect the commutator for an open circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the starter armature assembly. (c) Inspect the commutator for a short circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 2854 Fuel Pump Control Unit: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 252 Power Distribution Relay: Testing and Inspection ACC Relay 1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAIN BODY ECU (ACC RELAY) (a) Measure the resistance of the ACC relay circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the main body ECU. Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 6366 Page 143 Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 6. REMOVE LOWER INSTRUMENT PANEL (a) for Column Shift Type: Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 7. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) for Column Shift Type: Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 9. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (a) Remove the screw and duct. 10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY Testing and Inspection Valve Body: Testing and Inspection A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSPECTION 1. INSPECT SHIFT SOLENOID VALVE SL1 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. 2. INSPECT SHIFT SOLENOID VALVE S1 Page 7753 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 2693 Water Pump: Service and Repair Removal 1UR-FE COOLING: WATER PUMP: REMOVAL 1. REMOVE FAN SHROUD (a) Remove the fan shroud See: Radiator Cooling Fan/Service and Repair/Removal. 2. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT (a) Remove the water inlet with thermostat See: Thermostat/Service and Repair/Removal. 3. REMOVE FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Removal 5. REMOVE WATER BY-PASS PIPE (w/ Oil Cooler) (a) Remove the 2 bolts. (b) Disconnect the 4 water hoses and remove the water by-pass pipe. 6. REMOVE NO. 1 WATER BY-PASS HOSE (a) Remove the water by-pass hose. 7. DISCONNECT NO. 8 WATER BY-PASS HOSE (a) Disconnect the water by-pass hose. 8. DISCONNECT NO. 5 WATER BY-PASS HOSE (a) Disconnect the water by-pass hose. 9. REMOVE WATER INLET HOUSING Page 3423 Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (BUS BUFFER ECU) OK -- REPLACE BUS BUFFER ECU 10. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR) (a) Disconnect the J46 center airbag sensor connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU) A -Continue to next step. 11. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 1832 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Diagrams Trailer Brake Control Module: Diagrams Page 3094 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 1493 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 6708 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Door Control Switch (for Front LH) Power Door Lock Switch: Service and Repair Door Control Switch (for Front LH) Components DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): COMPONENTS Page 4785 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 542 Shift Interlock Control Module: Diagrams Service and Repair Fuel Pressure Release: Service and Repair 1UR-FE FUEL: FUEL SYSTEM: PRECAUTION CAUTION: * Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. * Do not smoke or be near an open flame when working on the fuel system. * Keep gasoline away from rubber and leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures. (1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. (2) Put a container under the connecting part of the pressure line. (3) Slowly loosen the connection. (4) Disconnect the connection. (5) Plug the connection with a rubber plug. (b) Observe these precautions when removing and installing the injectors: Page 1082 Headlamp Alignment Switch: Testing and Inspection LIGHTING: HEADLIGHT LEVELING SWITCH: INSPECTION 1. INSPECT HEADLIGHT LEVELING SWITCH (a) Connect the battery positive (+) lead to terminal 1 (B) and the negative (-) lead to terminal 5 (E). (b) Measure the voltage according to the value(s) in the table below. Standard Voltage: (c) Apply battery voltage to the connector and check the LED illumination condition. OK: (d) If the result is not as specified, replace the headlight leveling switch. Page 7215 Steering Column Control Module: Service and Repair Removal STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE UPPER STEERING COLUMN COVER (a) Remove the 2 screws. HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws. (b) Detach the 4 clips. (c) Detach the claw to remove the upper steering column cover. 3. REMOVE LOWER STEERING COLUMN COVER (a) Detach the 2 claws to remove the lower steering column cover. 4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal Page 8983 11. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 6277 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 8228 (f) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: * Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. * Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. HINT When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated front seat outer belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) CAUTION: Be sure to follow the procedures listed below when activating the seat belt pretensioner. (a) Remove the front seat outer belt. (1) Wind the seat belt with the retractor. (2) When the seat belt is sufficiently wound, cut the seat belt approximately 100 mm (3.94 in.) from the retractor, as shown in the illustration. HINT The seat belt is designed so that winding the seat belt before pretensioner activation will decrease the pulling power of the seat belt during pretensioner activation. (b) Check if SST is functioning properly. SST : 09082-00700 SST : 09082-00770 CAUTION: When activating a seat belt pretensioner, always use the specified SST. Page 1257 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 81 Power Mirror Control Module: Locations Crew Max Body Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 9027 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 943 (1) Insert the pin into the plate groove. (2) Attach the claw to install the main plate. (3) Install the 2 screws. (c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the damper servo. (d) Install the 4 screws and connect the 2 connectors. 9. INSTALL AIR DUCT (a) Install the duct with the 2 screws. 10. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY Page 6468 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 8680 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: SYSTEM DIAGRAM GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: SYSTEM DESCRIPTION 1. DESCRIPTION (a) A maximum of 3 kinds of transmitter code based systems (example: garage doors, gates and entry gates) can be registered with the vehicle's garage door opener. After registration, the vehicle's garage door opener can mimic the signal of the transmitter systems and the original transmitters of each transmitter system are not needed. Page 8313 Air Bag Deactivation Switch: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Components Transmission Speed Sensor: Service and Repair Components A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS Page 3405 C -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN Communication System/Problem Symptoms Table A -- Continue to next step. 10. CHECK DTC COMBINATION TABLE (V BUS CIRCUIT BRANCH WIRE OPEN PAST MALFUNCTION) (a) Based on the combination of stored CAN communication system DTCs, determine which ECUs and sensors have a communication stop malfunction See: CAN Communication System/Diagnosis System. NEXT -- Continue to next step. 11. PERFORM MALFUNCTION SIMULATION TEST (V BUS CIRCUIT MAIN WIRE PAST MALFUNCTION)* (a) Using the Techstream, clear all DTCs. (b) Perform a malfunction simulation test on all harnesses and connectors related to the V bus circuit main wire. (c) Check the DTCs that were output as a result of the malfunction simulation test. Then determine the malfunctioning area. NEXT -- Continue to next step. 12. ADJUST, REPAIR AND REPLACE NEXT -- Continue to next step. 13. CONFIRMATION TEST NEXT -- END Diagnosis System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: DIAGNOSIS SYSTEM 1. BUS CHECK (a) Select "CAN Bus Check" from the "System Select". 2. CHECK INSTALLED SYSTEMS (ECUS AND SENSORS) THAT USE CAN COMMUNICATION (a) Systems (ECUs and sensors) that use CAN communication vary depending on the vehicle's optional settings. Check which systems (ECUs and sensors) are installed on the vehicle. 3. DTC TABLE BY ECU HINT * In the CAN communication system, CAN communication system DTCs output by the ECU can be displayed by using the Techstream. 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 1010 Parking Brake Warning Switch: Diagrams Page 4866 Transmission Position Switch/Sensor: Diagrams Page 266 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 7585 "Case2" 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 Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 7945 (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press SST activation switch to deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The lower No. 1 instrument panel airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag with a deployed airbag. * Do not apply water to a lower No. 1 instrument panel airbag with a deployed airbag. * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Remove the lower No. 1 instrument panel airbag See: Removal and Replacement/Driver Side Knee Airbag Assembly/Removal. CAUTION: * When removing the lower No. 1 instrument panel airbag, wait at least 90 seconds after the ignition switch is turned off and the cable is disconnected from the negative (-) battery terminal before starting work. * When storing the lower No. 1 instrument panel airbag, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the lower No. 1 instrument panel airbag to a tire. Cross-sectional area of stripped wire harness section: 1.25 mm2 or more (0.00192 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the lower No. 1 instrument panel airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with a cross-sectional area of at least 1.25 mm2 (0.00192 in.2). HINT To calculate the cross-sectional area of the stripped wire harness section: Cross-sectional area = 3.14 x (Diameter)2 / 4 (1) Position the lower No. 1 instrument panel airbag inside a tire with the airbag deployment side facing inside. Page 457 Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 6654 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): REMOVAL 1. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 2. REMOVE CONSOLE BOX BEZEL Page 354 ^ 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 2253 * The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and Repair/Removal and Replacement/Removal 3. REMOVE FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Front Brake/Removal 4. REMOVE FRONT AXLE LH HUB BOLT (a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the front axle hub bolt. SST : 09650-17011 NOTICE: Do not damage the threads of the hub bolts. 5. INSTALL FRONT AXLE LH HUB BOLT (a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration. NOTICE: Install hub nuts to prevent damage to the hub bolts. (b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of the hub bolt head touches the axle hub. (c) Remove the washer and hub nut. NOTICE: Do not damage the threads of the hub bolts. 6. INSTALL FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Front Brake/Installation 7. CONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and Repair/Removal and Replacement/Installation 8. INSTALL FRONT WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) Page 7943 (1) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the tire. (h) Deploy the airbag. (1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the curtain shield airbag is tied to. (3) Press SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT The airbag is deployed as the LED of SST activation switch comes on. (i) Dispose of the curtain shield airbag. CAUTION: * The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag. * Do not apply water to a curtain shield airbag with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the curtain shield airbag from the tire. (2) Place the curtain shield airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Driver Side Knee Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY: DISPOSAL HINT When scrapping a vehicle equipped with the SRS or disposing of the lower No. 1 instrument panel airbag, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the service dept. of the distributor. CAUTION: * Never dispose of a lower No. 1 instrument panel airbag that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No. 1 instrument panel airbag. * The lower No. 1 instrument panel airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag with a deployed airbag. * Do not apply water, etc. to a lower No. 1 instrument panel airbag with a deployed airbag. * Always wash your hands with water after completing the operation. Page 4147 Page 5530 Transmission Speed Sensor: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL 1. REMOVE SPEED SENSOR NT (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. 2. REMOVE SPEED SENSOR SP2 (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. Page 5169 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 4176 Page 7948 HINT When scrapping a vehicle equipped with the SRS or disposing of the front passenger airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a front passenger airbag that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the front passenger airbag. * The front passenger airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front passenger airbag with a deployed airbag. * Do not apply water to a front passenger airbag with a deployed airbag. * Always wash your hands with water after completing the operation. * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the front passenger airbag See: Removal and Replacement/Front Passenger Airbag Assembly/Removal. (e) Install SST. (1) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect SST connector to the instrument panel wire assembly. Page 3199 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 1178 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Page 6659 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 6. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION 1. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL POWER OUTLET SOCKET ASSEMBLY (a) Attach the claw to install the power outlet socket. 3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 4874 Transmission Speed Sensor: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL 1. REMOVE SPEED SENSOR NT (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. 2. REMOVE SPEED SENSOR SP2 (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. Locations Hood Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Fuel Sender Gauge Assembly Fuel Gauge Sender: Service and Repair Fuel Sender Gauge Assembly Components 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: COMPONENTS Removal 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: REMOVAL 1. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Camshaft (for Bank 1) Camshaft: Service and Repair Camshaft (for Bank 1) Components 1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): COMPONENTS Removal Page 7953 * The front passenger airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front passenger airbag with a deployed airbag. * Do not apply water to a front passenger airbag with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the front passenger airbag from the tire. (2) Place the front passenger airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Steering Pad SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: DISPOSAL HINT When scrapping a vehicle equipped with the SRS or disposing of the steering pad, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a steering pad that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the steering pad. * The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a steering pad with a deployed airbag. * Do not apply water to a steering pad with a deployed airbag. * Always wash your hands with water after completing the operation. * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF STEERING PAD (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST. SST : 09082-00700 CAUTION: When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). (1) Connect SST to the battery. Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (2) Check the function of SST. Press SST activation switch, and check that the LED of SST activation switch comes on. Page 1897 Brake Fluid: Testing and Inspection BRAKE: BRAKE FLUID: ON-VEHICLE INSPECTION 1. CHECK BRAKE FLUID LEVEL IN RESERVOIR (a) Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 HINT The brake fluid level must always be adjust to the MAX line. Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. Up to 11/2009 Braking Sensor/Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 2051 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 989 (b) Disconnect the connector and remove the courtesy switch. Installation LIGHTING: FRONT DOOR COURTESY SWITCH: INSTALLATION HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL FRONT DOOR COURTESY SWITCH (a) Connect the connector. (b) Install the courtesy switch with the bolt. Page 2290 Variable Valve Timing Actuator: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. Page 2310 Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) (b) Remove the hexagon wrench from the No. 1 chain tensioner. 8. TIGHTEN CAMSHAFT TIMING GEAR LH (a) Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing gear with the bolt. Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf) (b) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear with the bolt. Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf) 9. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and Repair/Overhaul/Reassembly 10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (a) Install the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Installation. 11. INSPECT IGNITION TIMING See: Testing and Inspection/Engine 12. INSPECT ENGINE IDLE SPEED See: Testing and Inspection/Engine Page 1720 (e) * for 5 leaf spring 7. ADJUST CAMBER AND CASTER HINT After the camber has been adjusted, inspect the toe-in. (a) Loosen the toe adjusting cam bolt and camber adjusting cam nut. (b) Turn the toe adjusting cam and camber adjusting cam in both directions, and adjust the camber and caster to the center value. HINT The camber and caster should be as close as possible to the center value. Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 4978 Transmission Speed Sensor: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION 1. INSTALL SPEED SENSOR SP2 (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. 2. INSTALL SPEED SENSOR NT (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. Page 6355 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 535 Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL 1. REMOVE ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Disconnect the receiver connector. (b) Remove the bolt and receiver. Page 1339 Ignition Switch: Service and Repair Removal 1UR-FE STARTING: IGNITION SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal. (b) for Manual Tilt and Manual Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal. (c) for Power Tilt and Power Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal. 3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Disassembly 4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly 5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly 6. REMOVE IGNITION SWITCH ASSEMBLY (a) Detach the 2 claws and remove the ignition switch from the steering lock. Page 1601 Four Wheel Drive Selector Switch: Diagrams Page 3001 Variable Valve Timing Actuator Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE VVT SENSOR (a) Disconnect the 4 sensor connectors. (b) Remove the 4 bolts and 4 sensors. Page 5175 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Service and Repair Vehicle Lifting: Service and Repair INTRODUCTION: REPAIR INSTRUCTION: VEHICLE LIFT AND SUPPORT LOCATIONS 1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE (a) The vehicle must be unloaded before jacking up / lifting up the vehicle. Never jack up / lift up a heavily loaded vehicle. (b) When removing heavy parts such as the engine and transmission, the center of gravity of the vehicle may shift. To stabilize the vehicle, place a balance weight in a location where it will not roll or shift, or use a mission jack to hold the jacking support. 2. NOTICE FOR USING 4 POST LIFT (a) Follow the safety procedures outlined in the lift's instruction manual. (b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels. (c) Use wheel chocks to secure the vehicle. 3. NOTICE FOR USING JACK AND SAFETY STAND (a) Work on a level surface. Use wheel chocks at all times. (b) Use safety stands with rubber attachments as shown in the illustration. (c) Set the jack and safety stands to the specified locations of the vehicle accurately. (d) When jacking up the vehicle, first release the parking brake and move the shift lever to N. (e) When jacking up the entire vehicle: (1) When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels. (2) When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels. (f) When jacking up only the front or rear wheels of the vehicle: (1) Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels. (2) Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels. (g) When lowering a vehicle that only has its front or rear wheels jacked up: (1) Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels. (2) Before lowering the rear wheels, make sure wheel chocks are behind the front wheels. Page 1819 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. Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Page 2090 J/B No.3 - Instrument Panel Right Page 1526 Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch Page 2533 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 3553 CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: 4WD Control ECU Communication Stop Mode - 4WD Control ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (4WD CONTROL ECU BRANCH WIRE) (a) Disconnect the A25 4WD control ECU connector. Page 260 Page 2664 Radiator: Service and Repair Removal 1UR-FE COOLING: RADIATOR: REMOVAL 1. REMOVE FAN SHROUD (a) Remove the fan shroud See: Radiator Cooling Fan/Service and Repair/Removal. 2. DISCONNECT OUTLET RADIATOR HOSE See: Thermostat/Service and Repair/Removal 3. REMOVE RADIATOR SIDE DEFLECTOR RH (a) Using a clip remover, remove the 6 clips and side deflector. 4. REMOVE RADIATOR SIDE DEFLECTOR LH (a) Using a clip remover, remove the 6 clips and side deflector. (b) Disconnect the wire harness clamp. 5. REMOVE RADIATOR ASSEMBLY (a) Remove the 4 bolts and radiator. (b) Remove the radiator hose from the radiator. Page 6182 (a) Attach the claw to install the power outlet socket. (b) Connect the power outlet socket connector. 6. INSTALL CENTER FRONT SEAT ASSEMBLY (a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation. 7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. 10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Page 7431 (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 2021 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 1346 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Page 3596 Manifold Pressure/Vacuum Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSPECTION 1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Check the resistance. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the manifold absolute pressure sensor. Center Airbag Sensor Assembly (for Column Shift Type) Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 6847 Locations Power Distribution Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 684 Power Mirror Switch: Locations Power Mirror Control System (w/o Memory) MIRROR: POWER MIRROR CONTROL SYSTEM (w/o Memory): PARTS LOCATION Page 6210 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): REMOVAL 1. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 2. REMOVE CONSOLE BOX BEZEL Page 6246 Page 7481 (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) 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 9055 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 1420 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 8770 Speaker: Diagrams Front Door Speaker Page 7225 Steering Control Module: Service and Repair Removal POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE POWER STEERING ECU ASSEMBLY (a) Disconnect the power steering ECU connector. (b) Remove the nut and power steering ECU. Page 1710 Standard camber inclination (unloaded vehicle): for Double Cab of Long Deck Page 6587 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. Page 9396 13. Reinstall the body plugs for the cab mount bolt holes and then the carpet. 14. Test drive vehicle to confirm the condition has improved. Page 584 Integrated Accessory Switch Assembly: Testing and Inspection METER: DRIVE MONITOR SWITCH: INSPECTION 1. INSPECT DRIVE MONITOR SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (a) If the result is not as specified, replace the monitor switch. (b) Inspect the switch illumination. (1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 6 (ILL-). (2) Check that the light comes on. OK: LED comes on. (3) If the result is not as specified, replace the monitor switch. Components Intake Manifold: Service and Repair Components 1UR-FE INTAKE: INTAKE MANIFOLD: COMPONENTS Page 3339 Engine Control Module: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION 1. INSTALL GASKET (a) Clean the ECM seal's surface with non-residue solvent. (b) Attach a new gasket to the ECM. 2. INSTALL ECM (a) Install the ECM with the 4 bolts. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) NOTICE: * Make sure the gasket is not folded or caught on any area on the surrounding part. * Make sure there is no foreign matter caught between the gasket and surrounding part. * Do not damage the gasket. (b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors. NOTICE: * Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do this may cause the lock lever and terminals to break. * Do not twist the wire harness when connecting the ECM connectors. (c) Connect the wire harness clamp. 3. CONNECT CONNECTOR HOLDER BLOCK (a) Connect the connector holder block with the 3 bolts. Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf) Page 4004 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 7996 HINT Tape the screwdriver tip before use. 3. REMOVE LOWER NO. 2 STEERING WHEEL COVER (a) w/ Cruise Control: (1) Using a screwdriver, remove the No. 2 steering wheel cover. HINT Tape the screwdriver tip before use. (b) w/o Cruise Control: (1) Using a screwdriver, remove the No. 2 steering wheel cover. HINT Tape the screwdriver tip before use. 4. REMOVE STEERING PAD (w/ Steering Pad Switch) (a) Using a T30 "TORX" socket wrench, loosen the 2 screws until the groove along the screw circumference catches on the screw case. Page 7739 (c) Install the 6 screws and attach the 4 claws. (d) Install the packing. 3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Install the heater radiator unit. (b) Attach the 3 claws to install the heater clamp. (c) Install the plate with the 3 screws. Page 9374 7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts. 8. With the cab still raised install the new No.3 cab mounts. 9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to specification. Torque: 61 N*m (622 kgf*cm, 45 ft*lbf) Page 3381 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 7863 10. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the 4 screws and damper servo. (c) Remove the damper servo. (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. (d) Remove the damper servo. Page 3512 NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG SENSOR (CANH, CANL) OK -- REPLACE CENTER AIRBAG SENSOR 19. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) OK -Continue to next step. 20. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - BUS BUFFER ECU) NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (BUS BUFFER ECU) OK -- Continue to next step. 21. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU) Locations Gear Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 2033 J/B No.3 - Instrument Panel Right Page 318 Page 968 Dimmer Switch: Diagrams Page 6616 Auxiliary Power Outlet: Electrical Diagrams Power Outlet [120V] Power Outlet [120V] Up to 11/2009 Brake Fluid Pump Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6026 Torque : 133 Nm (1356 kgf-cm, 98 ft-lbf) HINT Hold the adjustable wrench against the vise and tighten the nut securely. (h) Remove SST 2 from the generator. (i) Turn SST 1-B, and remove SST 1-A and B. (j) Turn the pulley and check that the pulley moves smoothly. Page 357 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 6979 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 7546 * The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL LH 2. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 3. REMOVE REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Removal 4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 5. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 6. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 7. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 8. REMOVE REAR AXLE LH HUB BOLT (a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the hub bolt. SST : 09650-17011 9. INSTALL REAR AXLE LH HUB BOLT (a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration. NOTICE: Install hub nuts to prevent damage to the hub bolts. (b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of the hub bolt head touches the axle hub. (c) Remove the washer and hub nut. NOTICE: Do not damage the threads of the hub bolts. 10. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 11. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly Page 6285 Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Components Ignition Switch: Service and Repair Components 1UR-FE STARTING: IGNITION SWITCH: COMPONENTS Page 6167 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 4840 Standard condition: Indicator light [D] remains illuminated for 2 seconds and then turns off. (f) When using the Techstream: Return the shift lever to P and terminate the Active Test on the Techstream. (g) When not using the Techstream: Return the shift lever to P and disconnect SST from the DLC3. (h) Allow the engine to idle until the fluid temperature reaches 53 to 59°C (127 to 138°F). HINT The indicator [D] will come on again when the fluid temperature reaches 53°C (127°F) and will blink if it is higher than 59°C (138°F). (i) Remove the overflow plug and gasket with the engine idling. (j) Wait until the overflow slows to a trickle. NOTICE: If the fluid does not overflow, perform the following: (1) Remove the refill plug and gasket. (2) Refill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. (3) Wait until the overflow slows to a trickle. (4) Install a new gasket and the refill plug. Torque : 39 Nm (400 kgf-cm, 29 ft-lbf) (k) Install a new gasket and the overflow plug. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) 6. COMPLETE (a) Turn the ignition switch off. Page 9130 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 2454 Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity Without towing package ...................................................................................................................... .......................................................... 12.8 qt (12.1L) With towing package ........................................ .............................................................................................................................................. 13.9 qt (13.2L) Page 7574 Page 988 Removal LIGHTING: FRONT DOOR COURTESY SWITCH: REMOVAL HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT DOOR COURTESY SWITCH (a) Remove the bolt. Page 293 Engine Room R/B, J/B - Engine Compartment Left Page 7354 (a) Install a new bush to the leaf spring. (1) Install the bushing while aligning it with the matchmarks so that its openings are as shown in the illustration. NOTICE: Be sure to install each bushing to the correct positions. (b) Use SST and a press, press both bushes into the leaf spring. SST : 09710-28012 09710-07062 SST : 09710-30041 09710-03211 NOTICE: Align SST, which presses the bush, to the outer casing of the bush. LIN Communication System Information Bus: Locations LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 1987 Page 4615 Ignition Switch: Service and Repair Installation 1UR-FE STARTING: IGNITION SWITCH: INSTALLATION 1. INSTALL IGNITION SWITCH ASSEMBLY (a) Attach the 2 claws to install the ignition switch to the steering lock. 2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Reassembly 3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly 4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly 5. INSTALL STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation. (b) for Manual Tilt and Manual Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation. (c) for Power Tilt and Power Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 9019 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 6905 Page 5061 28. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING (a) Using a snap ring expander, remove the snap ring. (b) Using SST, a brass bar and press, press out the bearing. SST : 09950-00020 SST : 09950-70010 09951-07100 SST : 09950-60010 09951-00450 NOTICE: Do not damage the bearing. 29. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB (a) Check for wear and damage to the clutch hub and clutch sleeve. (b) If necessary, replace them. (c) Check that the clutch sleeve slides smoothly on the clutch hub. Page 6484 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 3189 Body Control Module: Diagrams Page 9060 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 8464 (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 5. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 2069 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 7764 (4) for Driver Side: Install the 3 bolts. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) (5) for Driver Side: Install the 3 caps. (b) Attach the clamps and connectors to the wire harness. (c) Install the 8 bolts, 2 screws and 4 nuts. 3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. Page 7784 Refrigerant: Fluid Type Specifications REFRIGERANT TYPE Refrigerant............................................................................................................................................ ......................................................HFC-134a (R134a) Page 2157 Tire Pressure Sensor: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so that the print surface can be seen. NOTICE: * Check that there is no visible deformation, damage or other abnormalities on the tire pressure warning valve and transmitter. * Check that there is no foreign matter on the inner grommet and around the rim hole. * If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be damaged or fail to transmit signals when running at a high speed. * If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before installation. * The transmitter ID registration must be performed for all tire pressure warning valve and transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do not need to be replaced before performing the transmitter ID registration See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration * It is necessary to perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been replaced. (b) If reusing the tire pressure warning valve and transmitter: Install a new grommet. HINT A new tire pressure warning valve and transmitter is supplied with a grommet. (c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut. Page 9350 (c) w/o Rear Fender Mudguard: Remove the rear wheel house liner (rear). (1) Remove the 2 screws. (2) Remove the 7 clips and wheel house liner. (d) w/ Rear Fender Mudguard: Remove the rear wheel house liner (rear). (1) Remove the mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and Repair/Removal. (2) Remove the screw. (3) Remove the 7 clips and wheel house liner. Page 506 Steering Control Module: Service and Repair Removal POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE POWER STEERING ECU ASSEMBLY (a) Disconnect the power steering ECU connector. (b) Remove the nut and power steering ECU. Page 3086 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 9046 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 4284 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. Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5898 Traction Control Switch: Service and Repair Removal BRAKE CONTROL: VSC OFF SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE VSC OFF SWITCH (a) Disconnect the VSC OFF switch connector. (b) Using a screwdriver, detach the 2 claws and remove the VSC OFF switch from the lower instrument panel finish panel LH. Page 6204 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 10. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL POWER OUTLET SOCKET ASSEMBLY Page 5192 (b) Install the O-ring to the axle shaft. (c) Install the rear axle shaft and parking brake plate with the 4 nuts. Torque : 60 Nm (612 kgf-cm, 44 ft-lbf) 3. CONNECT REAR SPEED SENSOR LH See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Speed Sensor/Installation 4. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 5. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 6. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 7. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 8. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 9. CHECK PARKING BRAKE INSTALLATION See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 10. INSTALL REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Installation 11. ADJUST PARKING BRAKE SHOE CLEARANCE See: Brakes and Traction Control/Parking Brake System/Adjustments 12. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH (a) Connect the rear disc brake cylinder and install 2 new bolts. Torque : 95 Nm (969 kgf-cm, 70 ft-lbf) NOTICE: * Do not twist the flexible hose. * Make sure that the bolts are free from damage and foreign matter. * Do not overtighten the bolts. 13. CONNECT REAR BRAKE FLEXIBLE HOSE (a) Set the flexible hose to the connecting point with the brake tube, and then install a new clip. Page 7021 *: for 5 leaf spring Standard Toe-in for Regular Cab of Standard Deck Page 8384 between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 9. INSTALL FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): COMPONENTS Page 7261 Steering Column Control Module: Service and Repair Removal STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE UPPER STEERING COLUMN COVER (a) Remove the 2 screws. HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws. (b) Detach the 4 clips. (c) Detach the claw to remove the upper steering column cover. 3. REMOVE LOWER STEERING COLUMN COVER (a) Detach the 2 claws to remove the lower steering column cover. 4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal Page 317 Body Control Module: Diagrams Page 7918 Air Bag: Testing and Inspection Front Seat Side Airbag Assembly (for Fold Down Seat Type) SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold Down Seat Type): ON-VEHICLE INSPECTION 1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat with a new one: Cuts, minute cracks or marked discoloration on the front seatback around the front seat side airbag. 2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat side airbag with a new one: * Cuts, minute cracks or marked discoloration on the front seat side airbag. * Cracks or other damage to the wire harness or connector. CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow the correct procedure. Page 1976 Engine Room R/B, J/B - Engine Compartment Left Page 4181 Testing and Inspection Thermostat: Testing and Inspection 1UR-FE COOLING: THERMOSTAT: INSPECTION 1. INSPECT WATER INLET SUB-ASSEMBLY WITH THERMOSTAT HINT The valve opening temperature is stamped on the water inlet with thermostat. (a) Immerse the water inlet with thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Standard valve opening temperature: 80 to 84°C (176 to 183°F) (c) If the valve opening temperature is not within the specified range, replace the water inlet sub-assembly with thermostat. (d) Check the valve lift. Standard valve lift: 10 mm (0.394 in.) or more at 95°C (203°F) (e) If the valve lift is not as specified, replace the water inlet sub-assembly with thermostat. (f) Check that the valve is fully closed when the water inlet with thermostat is at a low temperature (below 77°C (171°F)). If it is not fully closed, replace the water inlet sub-assembly with thermostat. Locations Leak Detection Pump: Locations 1UR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION Page 4298 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 7912 Air Bag: Diagrams Curtain Shield Airbag Squib Circuit Page 7067 (a) Check the steering angle sensor zero point calibration See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/C Code Charts/C1290. Page 6850 Tailgate Wire Front Seat Wire Page 5518 Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch Page 3591 B -- GO TO VC OUTPUT CIRCUIT See: Testing and Inspection/Component Tests and General Diagnostics/VC Output Circuit A -- Continue to next step. 7. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Disconnect the ECM connector. (b) Disconnect the combination meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal Page 4042 (1) Disconnect the clamp and No. 3 air injection system hose. (2) Using a clip remover, remove the clamp from the body panel. (b) Front Fender RH Inside: (1) Disconnect the No. 3 air injection system hose from the air pump. (2) Using a clip remover, remove the clamp from the body panel. 5. REMOVE AIR PUMP ASSEMBLY WITH BRACKET (a) Disconnect the 2 air pump connectors and detach the 3 wire harness claws. (b) Remove the 2 bolts, 2 nuts and air pump. 6. REMOVE AIR PUMP INLET (a) Remove the 2 bolts, slide the 2 clips off of the No. 1 air injection system hoses, disconnect the hoses and remove the air pump inlet. 7. DISCONNECT NO. 1 AIR INJECTION SYSTEM HOSE (a) Disconnect the 2 No. 1 air injection system hoses. 8. REMOVE AIR PUMP ASSEMBLY (a) Using a clip remover, detach the 2 clamps and remove the air pump from the bracket. Page 3075 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Locations Door Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 3796 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 5915 Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamp, do not twist the wire harness. * Make sure the clamp's rotation stopper touches the installation position. (d) Attach the 3 clips (labeled E). NOTICE: * When installing the clips, do not twist the wire harness. * When installing the clips, securely insert them as shown in the illustration. (e) Connect the speed sensor connector (labeled F). NOTICE: Securely connect the connector. 4. INSTALL FRONT SKID CONTROL SENSOR CLAMP RH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle. 5. INSTALL FRONT SPEED SENSOR RH (a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E). Locations Shift Interlock Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 7642 Push the terminal retainer down to the temporary lock position. Page 7645 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 3355 Page 2815 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 6. INSPECT IGNITION SWITCH See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0617 NG -- REPLACE IGNITION SWITCH See: Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Service and Repair/Removal OK -- Continue to next step. 7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the cable from the battery positive terminal. (c) Remove the integration relay from the engine room relay block. (d) Disconnect the integration relay connectors. Airbag Cutoff Switch Air Bag Deactivation Switch: Diagrams Airbag Cutoff Switch Page 70 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL 1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Page 2557 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 5404 Fluid - Transfer Case: Service and Repair JF1A TRANSFER: TRANSFER OIL: REPLACEMENT 1. DRAIN TRANSFER OIL (a) Remove the 4 bolts and lower transfer case protector. (b) Remove the filler plug and gasket. (c) Remove the drain plug and gasket, and drain the transfer oil. 2. ADD TRANSFER OIL (a) Install a new gasket and the drain plug. Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) (b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole. NOTICE: * Pour oil slowly. * Pour oil a little at a time, waiting several minutes between each addition of oil. (c) Wait approximately 5 minutes and check that the oil level has not changed. (d) Install a new gasket and the filler plug. Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) (e) Install the lower transfer case protector with the 4 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) Locations Transmission Mode Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 8442 Antenna, Radio: Service and Repair Satellite Radio Antenna Components AUDIO / VISUAL: SATELLITE RADIO ANTENNA: COMPONENTS Removal AUDIO / VISUAL: SATELLITE RADIO ANTENNA: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE ROOF HEADLINING ASSEMBLY (a) for Double Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (b) for CrewMax: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. (c) for Regular Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. 3. REMOVE SATELLITE RADIO ANTENNA ASSEMBLY (a) Disconnect the connector. (b) Detach the 3 clamps. (c) Remove the nut. Page 5957 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 5978 Page 7054 Standard camber inclination (unloaded vehicle): for Double Cab of Long Deck Page 6945 Relay Box: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Page 7078 6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU (a) Disconnect the 2 ECU connectors. (b) Remove the 2 screws and ECU. Page 7088 Steering Control Module: Service and Repair Installation POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION 1. INSTALL POWER STEERING ECU ASSEMBLY (a) Install the power steering ECU with the nut. Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf) (b) Connect the power steering ECU connector. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 6473 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 7870 7. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. 8. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the servo motor. (1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to install the main plate. (2) Install the 2 screws. (b) Install the servo motor. Air Conditioning System (for Automatic Air Conditioning System) Compressor Speed Sensor: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 3179 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 2970 Removal 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL CAUTION: * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 3. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Disconnect the heated oxygen sensor connector and 2 clamps. (b) Disconnect the air fuel ratio sensor connector. (c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH. 4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Using SST, remove the sensor. SST : 09224-00010 Page 8211 The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Front Seat Outer Belt Assembly (for CrewMax) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): INSPECTION 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY CAUTION: Do not disassemble the retractor. (a) Before installing the seat belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) for Passenger's Seat only: Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Front Seat Outer Belt Assembly (for Double Cab) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY CAUTION: Do not disassemble the retractor. (a) Before installing the seat belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Locations Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Locations Shock Sensor: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 1480 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Diode (Front Door Courtesy Light) Diode: Diagrams Diode (Front Door Courtesy Light) Page 6286 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 5912 (d) Remove the 3 bolts (labeled E), 3 harness clamps (labeled F) and sensor wire. 4. REMOVE FRONT SPEED SENSOR LH (a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the knuckle. 5. REMOVE FRONT SKID CONTROL SENSOR CLAMP LH (a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle. 6. REMOVE FRONT SKID CONTROL SENSOR WIRE RH (a) Disconnect the connector (labeled A) from the front speed sensor. (b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C). Page 283 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 4348 (c) Check for leakage. (1) In the condition above, disconnect the tester probes of SST (wire) from the battery and check for fuel leakage from the injector. Standard fuel drop: 1 drop or less in 12 minutes Page 3249 Data Link Connector: Connector Views Page 3371 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 7496 Tire Pressure Sensor: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL 1. REMOVE TIRE 2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Remove the valve core and cap, and release the air from the tire. (b) After ensuring that a sufficient amount of air has been released, remove the nut and washer that is used to secure the tire pressure warning valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire. HINT Keep the removed cap, valve core, nut and washer. (c) Disengage the bead using the shoe of a tire remover. NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due to interference between the sensor and tire bead. (d) Remove the bead on the upper side. (e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on the lower side. HINT * The grommet is a non-reusable part. * Check that there are no cracks or damage on the grommet. If any damage is found, replace the washer and nut. Page 1332 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 3846 Removal 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL CAUTION: * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 3. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Disconnect the heated oxygen sensor connector and 2 clamps. (b) Disconnect the air fuel ratio sensor connector. (c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH. 4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Using SST, remove the sensor. SST : 09224-00010 Page 9330 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 6014 (b) If necessary, replace the generator rotor assembly. Page 1029 Brake Light Switch: Testing and Inspection LIGHTING: STOP LIGHT SWITCH: INSPECTION 1. INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch assembly. Page 3430 NEXT -- Continue to next step. 7. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - COMBINATION METER ECU) (a) Disconnect the J84 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU) OK -- Continue to next step. 8. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - MAIN BODY ECU) (a) Disconnect the J96 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU) OK -- Continue to next step. 9. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A46 No. 1 junction connector connector. Page 4543 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Page 3483 A -- Continue to next step. 5. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH ACTUATOR BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (SKID CONTROL ECU WITH ACTUATOR) OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal 6. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR) (a) Disconnect the J6 steering angle sensor connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU) A -Continue to next step. 7. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Page 422 Fuel Pump Control Unit: Locations Crew Max Body Specifications Fuel Pressure: Specifications FUEL PRESSURE Page 1697 Alignment: Service and Repair SUSPENSION: FRONT WHEEL ALIGNMENT: ADJUSTMENT NOTICE: For vehicles equipped with VSC, if wheel alignment has been adjusted, and if suspension or underbody components have been removed/installed or replaced, be sure to perform the following initialization procedure in order for the system to function normally: * Check that the steering wheel is in the centered position. * Disconnect the negative battery terminal for more than 2 seconds. * Reconnect the negative battery terminal. * Perform zero point calibration of the yaw rate and deceleration sensor and test mode inspection See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning 1. INSPECT TIRE (a) Inspect the tires See: Wheels and Tires/Testing and Inspection/Component Tests and General Diagnostics. 2. MEASURE VEHICLE HEIGHT NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specification. (a) Press down on the vehicle several times to stabilize the suspension, and then measure the vehicle height. Standard vehicle height (unloaded vehicle): for Regular Cab of Standard Deck Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Stereo Jack Adapter Assembly (for Column Shift Type) Auxiliary Input / Output Jack: Service and Repair Stereo Jack Adapter Assembly (for Column Shift Type) Components AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Column Shift Type): COMPONENTS Specifications Axle Nut: Specifications FRONT AXLE HUB NUT LH (for 4WD) Using a 39 mm socket wrench, install the hub nut. Torque.................................................................................................................................................. ...............................338 Nm (3446 kgf-cm, 249 ft-lbf) Components Central Control Module: Service and Repair Components AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: COMPONENTS Page 9110 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 4327 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Page 7451 Tire Pressure Sensor: Service and Repair Disposal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire pressure warning valve and transmitter, remove the battery and dispose of it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Use the tip of a screwdriver to pry off the back cover. (b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that connect the battery to the base board. Page 6233 Page 8896 2. REMOVE REAR DOOR SCUFF PLATE RH (a) Detach the 8 claws and 2 clips, and remove the scuff plate. 3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 5. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. INSTALL REAR DOOR SCUFF PLATE RH Page 4768 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 7606 Blower Motor: Connector Views Page 4108 (m)Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (o) Stop the engine. (p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Standard fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or higher (q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and carefully remove SST and the fuel tube connector to prevent gasoline from spraying. (s) Reconnect the fuel tube (fuel tube connector). (t) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. Page 6928 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 8252 (a) Attach the 7 clips and 2 claws to install the pillar garnish. (b) Install the seat belt anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Attach the 2 claws to install the cover. 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 7. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 8. INSTALL FRONT SEAT ASSEMBLY (a) for Manual Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. (b) for Power Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. Page 6215 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 6. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION 1. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL POWER OUTLET SOCKET ASSEMBLY (a) Attach the claw to install the power outlet socket. 3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 8253 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): COMPONENTS Locations Power Steering Pressure Control Valve: Locations POWER STEERING: POWER STEERING SYSTEM (for 1UR-FE): PARTS LOCATION Locations Starter Relay: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Specifications Power Steering Fluid: Specifications Power Steering Fluid Type Type ......................................................................................................................................................... Automatic Transmission Fluid DEXRON II or III Page 7169 Page 5302 NOTICE: When measuring dimension B, fix the spider and spider bearings in a vise and hold them firmly together. (d) w/o Grease Fitting Spider Bearing: (1) Select snap rings to make dimensions A and B the same. Snap ring type for steel yoke: Snap ring type for aluminum yoke: NOTICE: * Use new snap rings. * If possible, use snap rings of the same thickness for both sides. (e) w/ Grease Fitting Spider Bearing: (1) Select snap rings to make dimensions A and B the same. Snap ring type: NOTICE: Page 7353 Suspension Spring ( Coil / Leaf ): Overhaul Disassembly SUSPENSION: REAR LEAF SPRING: DISASSEMBLY 1. REMOVE REAR SPRING LEAF BUSH (a) Put matchmarks on the bush on the front side of the vehicle. (1) Align the leaf spring with the openings and put matchmarks. (b) Use SST and a press, press out the bushes on both sides of the vehicle. SST : 09950-60010 09951-00350 SST : 09950-70010 09951-07150 NOTICE: Do not erase the matchmark on the leaf spring when removing the bush on the front side of the vehicle. Reassembly SUSPENSION: REAR LEAF SPRING: REASSEMBLY 1. INSTALL REAR SPRING LEAF BUSH Page 3175 Air Flow Meter/Sensor: Diagrams Page 7750 Hose/Line HVAC: Service and Repair From 11/2009 AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS Page 8866 Alarm Module: Locations Theft Deterrent System THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 8382 Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 4. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 6. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 8. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 9. REMOVE FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 10. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Page 452 Page 7257 Steering Column Control Module: Diagrams Page 5299 NOTICE: * Use new snap rings. * If possible, use snap rings of the same thickness for both sides. (f) Temporarily install the spider and 2 universal joint spider bearings into the flange yoke. (g) Using SST, press the universal joint spider bearing into the flange yoke until the groove can be seen. SST : 09950-40011 09951-04020 09952-04010 09953-04020 09954-04020 09955-04051 09957-04010 SST : 09950-60010 09951-00290 SST : 09336-16010 NOTICE: Confirm that the universal joint spider moves smoothly while pressing in the bearing. (h) Using needle-nose pliers, install the previously selected snap ring into the groove of the yoke. HINT Locations Power Distribution Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 1317 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 5168 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 8103 Page 3548 NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE MAIN BODY ECU Skid Control ECU Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Skid Control ECU Communication Stop Mode - Skid Control ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes Page 6657 (a) for AC Power Supply: Connect the clamp. (b) Install the bezel with the 3 screws. 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Components OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS Page 9385 8. With the cab still raised install the new No.3 cab mounts 9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to specification. Torque: 61 N*m (622 kgf*cm, 45 ft*lbf) 10. Lower the cab back onto the No.3 cab mount. 11. Install the new bolt through the No.3 cab mount and install the NEW larger washer and NEW nut and torque to specifications. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) Locations Manifold Pressure/Vacuum Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 1824 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 7867 Evaporator Temperature Sensor / Switch: Service and Repair Reassembly AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: REASSEMBLY 1. INSTALL NO. 1 COOLER THERMISTOR NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted. (a) Install the sensor to a location that is 1 fin to the right or left of its previous location. 2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (a) Install the evaporator to the blower case (front side). (b) Install the blower case (back side). Components Control Module: Service and Repair Components JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS Page 9407 Standard: 2. INSTALL RADIATOR GRILLE (OR FRONT PANEL) EMBLEM (a) Attach the 3 claws to install the radiator grille (or front panel) emblem. Page 1407 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 4613 Page 5992 Neutral Safety Switch: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the switch to the manual valve shaft. (b) Temporarily install the bolt. (c) Install a new lock washer and the nut. Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf) (d) Temporarily install the control shaft lever RH. (e) Turn the control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position. (f) Align the groove with the neutral basic line. Page 7292 (d) Install the rack bush onto the power steering rack. 5. INSTALL CYLINDER END STOPPER (a) Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing. (b) Install a new wire into the cylinder end stopper. (c) Using a screwdriver, turn the cylinder end stopper clockwise by 400 to 500°. 6. AIR TIGHT TEST (a) Install SST onto the rack housing. (b) Apply a vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds. (c) Check that there is no change in the vacuum. If there is any change in the vacuum, check whether the oil seals are installed correctly. 7. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Coat the control valve upper bearing and a new control valve upper oil seal with power steering fluid. (b) Using SST and a press, install the control valve upper oil seal. SST : 09950-60010 Page 955 Refrigerant Pressure Sensor / Switch: Service and Repair Installation AIR CONDITIONING: PRESSURE SWITCH: INSTALLATION 1. INSTALL PRESSURE SWITCH (a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pressure switch. Compressor oil: ND-OIL 8 or equivalent (b) Install the O-ring on the pressure switch. (c) Install the switch. Torque : 10.8 Nm (110 kgf-cm, 8 ft-lbf) (d) Connect the connector. 2. CHARGE REFRIGERANT See: Heating and Air Conditioning/Service and Repair 3. WARM UP ENGINE See: Heating and Air Conditioning/Service and Repair 4. CHECK FOR LEAKAGE OF REFRIGERANT See: Heating and Air Conditioning/Service and Repair Page 8737 Additional SSTs may be ordered by calling 1-800-933-8335. Repair Procedure 1. Verify the condition in the Introduction. 2. Perform diagnostic troubleshooting to confirm the problem is related to the condition described in this TSB. Refer to the Technical Information System (TIS), Accessory - Accessory Diagnostic Guide "2004-2011 All Vehicles XM Satellite Radio Tuner 86180-0W030 Troubleshooting Guide" 3. Order a replacement XM Satellite Radio Receiver through the Pioneer exchange program. For information regarding the satellite radio warranty, refer to TIS, Reference Information Warranty Policy & Procedures -"Policy 4.28: Satellite Radio Warranty" Locations Trailer Lighting Relay: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 3362 Locations Relay Box: Locations Engine Compartment Page 7107 Tire Pressure Module: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL NOTICE: * It is necessary to perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. * When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU using the intelligent tester or Techstream and write them down before removal. 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the ECU connector. (b) Remove the 2 nuts and ECU. Page 601 Removal PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT END PANEL LH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 3. REMOVE FRONT END PANEL RH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 4. REMOVE FRONT BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 7. REMOVE FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 8. REMOVE FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 9. REMOVE FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 10. REMOVE FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 11. REMOVE NO. 1 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT Standard............................................................................................................................................... ........................................600 +/-30 g (21.2 +/-1.1 oz.) Page 6469 "Case2" 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 5005 (a) Remove the 2 bolts and 2 temperature sensor clamps. (b) Disconnect the 2 ATF temperature sensors. (c) Disconnect the 9 solenoid valve connectors. (d) Detach the wire harness from the 2 clamps. 5. REMOVE TRANSMISSION WIRE (a) Disconnect the wire connector. (1) Detach the claw, press down the lever, and then disconnect the transmission wire connector. (b) Remove the bolt and pull out the transmission wire. (c) Remove the O-ring from the transmission wire connector. Page 8898 Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS Page 6146 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 7955 (3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window. (4) Maintaining enough clearance for SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage SST wire harness. (5) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press SST activation switch and deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a steering pad with a deployed airbag. * Do not apply water to a steering pad with a deployed airbag. * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF STEERING PAD (WHEN NOT INSTALLED IN VEHICLE) CAUTION: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. SST : 09082-00700 SST : 09082-00820 (b) Remove the steering pad See: Removal and Replacement/Steering Pad/Removal. CAUTION: * When removing the steering pad, work must be started 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery. * When storing the steering pad, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the steering pad to the disc wheel. Page 9254 (b) Disconnect the connector. 6. REMOVE REAR DOOR ARMREST COVER LH 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Remove the 2 screws. (b) Using a clip remover, remove the clip. (c) Detach the 9 clips and remove the trim cover. Then disconnect the connector. (d) Disconnect the 2 cables from the inside handle. From 11/2009 ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): DISASSEMBLY REAR DOOR TRIM BOARD SUB-ASSEMBLY LH 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel. HINT Tape the screwdriver tip before use. Page 8378 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 2772 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 8873 Alarm Module: Service and Repair Removal THEFT DETERRENT: THEFT WARNING ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE GLASS BREAKAGE SENSOR ECU Page 4080 EGR Cooler: Service and Repair Removal 1UR-FE EMISSION CONTROL: EGR COOLER: REMOVAL 1. REMOVE INTAKE MANIFOLD ASSEMBLY (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY (a) Disconnect the No. 4 water by-pass hose. (b) Disconnect the hose and remove the 2 bolts and No. 3 water by-pass pipe. 3. DISCONNECT NO. 8 WATER BY-PASS HOSE (a) Disconnect the No. 8 water by-pass hose. 4. DISCONNECT NO. 11 WATER BY-PASS HOSE (a) Disconnect the No. 11 water by-pass hose. 5. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 6. REMOVE EGR COOLER ASSEMBLY (a) Remove the 2 bolts and EGR cooler. 7. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY (a) Remove the 2 bolts, No. 2 EGR pipe and gasket. Page 9227 6. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (a) Detach the 3 clips and front lower door frame bracket garnish. 7. REMOVE COURTESY LIGHT ASSEMBLY (w/ Power Window) (a) Detach the claw and remove the courtesy light. (b) Disconnect the connector. 8. REMOVE FRONT DOOR ARMREST COVER LH 9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Remove the 2 screws. (b) Using a clip remover, remove the clip. (c) Detach the 10 clips and remove the trim cover. Then disconnect the connector. (d) Disconnect the 2 cables from the inside handle. Page 1310 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 6584 Page 5264 Drive/Propeller Shaft: Component Tests and General Diagnostics Front Propeller Shaft Assembly PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: INSPECTION 1. INSPECT FRONT PROPELLER SHAFT ASSEMBLY (a) Check that the propeller shaft is not damaged or deformed. * If necessary, replace the propeller shaft. (b) Using a dial indicator, check the propeller shaft runout. Maximum runout: 0.61 mm (0.0240 in.) 2. INSPECT UNIVERSAL JOINT SPIDER BEARING (a) Check that the joints move smoothly. (b) Check the spider bearings for wear and damage. (c) Check the spider bearing axial play by turning the yoke while holding the shaft tightly. Maximum bearing axial play: 0.05 mm (0.00197 in.) * If necessary, replace the spider bearing. Propeller Shaft Assembly PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): INSPECTION 1. INSPECT PROPELLER SHAFT ASSEMBLY (for 2 Joint Type) (a) Using a dial indicator, measure the propeller shaft runout. Maximum runout: 1.02 mm (0.0402 in.) * If the shaft runout is more than the maximum, replace the propeller shaft assembly. Page 4260 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 7841 Cabin Temperature Sensor / Switch: Testing and Inspection AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): INSPECTION 1. INSPECT ROOM TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the thermistor. NOTICE: * Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. * When measuring the resistance, the sensor temperature must be the same as the ambient temperature. Page 6724 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 1457 Seat Position Sensor: Service and Repair Removal SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Removal. 2. REMOVE SEAT POSITION SENSOR (a) Using a T30 "TORX" socket wrench, remove the screw and seat position sensor with sensor protector. (b) Disconnect the connector. (c) Remove the seat slide position sensor protector from the seat position sensor. Page 7935 * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Remove the front seat side airbag See: Removal and Replacement/Front Seat Side Airbag Assembly (except Fold Down Seat Type)/Removal . (c) Using a service-purpose wire harness for the vehicle, tie down the front seat side airbag to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.00193 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2). HINT To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Install the 2 nuts to the front seat side airbag. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 1684 *: for 5 leaf spring Standard Camber Inclination for Regular Cab of Standard Deck Page 3064 Page 9201 Page 7232 Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch System Diagnosis Radiator Cooling Fan: Testing and Inspection 1UR-FE COOLING: FAN: INSPECTION 1. INSPECT FLUID COUPLING ASSEMBLY (a) Check the fluid coupling for damage or silicon oil leaks. If necessary, replace the fluid coupling assembly. Page 5042 (c) Install the 2 adjusting nut locks with the 2 bolts. (d) Using a dial indicator, measure the runout of the ring gear. Maximum runout: 0.05 mm (0.00197 in.) (e) If the runout is greater than the maximum, replace the ring gear. (f) Remove the 2 bolts and adjusting nut locks. (g) Remove the 2 bearing caps, 2 adjusting nuts and differential case assembly. 7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST and a press, press in the bearing (outer race). SST : 09950-60020 09951-00710 SST : 09950-70010 09951-07150 8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST and a press, press in the bearing (outer race). SST : 09950-60020 09951-00890 SST : 09950-70010 09951-07150 9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (a) Install the plate washer onto the drive pinion. Page 3731 HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor. (b) WAVEFORM 1: Page 8004 Air Bag Control Module: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 4272 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 Windshield Deicer System Heated Glass Element Switch: Locations Windshield Deicer System WINDSHIELD / WINDOWGLASS: WINDSHIELD DEICER SYSTEM: PARTS LOCATION Components Fuel Pump Control Unit: Service and Repair Components 1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS Page 1206 Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION 1. INSPECT AIR FUEL RATIO SENSOR (a) Disconnect the 2 sensor connectors. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the air fuel ratio sensor. (d) Connect the 2 sensor connectors. Page 7962 SST : 09082-00700 SST : 09082-00802 09082-10801 09082-40800 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Move SST at least 10 m (32.8 ft.) away from the vehicle rear side window. (4) Maintaining enough clearance for SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage SST wire harness. (5) Connect the red clip of SST to the battery positive (+) terminal and black clip of SST to the battery negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press SST activation switch and deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag. * Do not apply water to a curtain shield airbag with a deployed airbag. * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) CAUTION: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 1941 (f) Remove the oil filter element and O-ring from the oil filter cap. NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent damage to the cap's O-ring groove. 4. INSTALL OIL FILTER ELEMENT (a) Clean the inside of the oil filter cap, its threads and its O-ring groove. (b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap. (c) Set a new oil filter element to the oil filter cap. (d) Remove any dirt or foreign matter from the installation surface of the engine. (e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap. (f) Using SST, tighten the oil filter cap. SST : 09228-06501 Torque : 25 Nm (255 kgf-cm, 18 ft-lbf) NOTICE: * When tightening the oil filter cap, do not remove the oil filter bracket clip. * Make sure that the oil filter is installed securely as shown in the illustration. * Be careful that the O-ring does not get caught between any surrounding parts. Page 3223 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 208 Page 1751 (3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. (4) Pinch the connector and disconnect the connector and pipe. (5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out. NOTICE: Do not use any tools. (6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. (7) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag. (e) Observe these precautions when connecting the fuel tube connector (for Quick Type). (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe. (3) After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected. Page 8677 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 290 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 6243 Page 1382 Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Front Airbag Sensor SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE INSPECTION 1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 379 Engine Control Module: Diagrams Locations Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 5863 Braking Sensor/Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Air Conditioning System (for Automatic Air Conditioning System) Control Module HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 721 (a) Install the switch with the 2 screws. 2. INSTALL FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 3. INSTALL RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 4. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 5. INSTALL FRONT SEAT ASSEMBLY LH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. Page 7846 Cabin Temperature Sensor / Switch: Service and Repair Installation AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): INSTALLATION 1. INSTALL ROOM TEMPERATURE SENSOR (a) Attach the 2 claws to install the sensor. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 3. INSTALL INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 5. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Components Power Steering Pressure Switch: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: COMPONENTS Page 2027 Fuse Block: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 5436 2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (a) Remove the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal. 3. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and Repair/Overhaul/Disassembly 4. REMOVE TRANSFER CASE FRONT OIL SEAL (a) Using SST, tap out the oil seal. SST : 09308-00010 NOTICE: Be careful not to damage the oil seal and transfer front case contact surface. 5. INSTALL TRANSFER CASE FRONT OIL SEAL (a) Apply transfer oil to the spline area of the output shaft. (b) Using SST and a hammer, tap in the oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0591 in.) from the case upper surface. SST : 09316-60011 09316-00011 6. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and Repair/Overhaul/Reassembly 7. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (a) Install the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation. 8. ADD TRANSFER OIL See: Fluid - Transfer Case/Service and Repair 9. CHECK TRANSFER OIL See: Fluid - Transfer Case/Testing and Inspection 10. CHECK FOR TRANSFER OIL LEAK Page 8849 From 11/2009 AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): COMPONENTS Locations Door Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 8385 Page 8847 4. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Disassembly 6. REMOVE REAR DOOR ARMREST COVER LH 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Disassembly 8. REMOVE REAR NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 3 screws and speaker. NOTICE: Do not touch the cone part of the speaker. 9. REMOVE REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers) (a) Detach the 3 claws and remove the speaker. Installation AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers) (a) Attach the 3 claws to install the speaker to the door trim board. 2. INSTALL REAR NO. 1 SPEAKER ASSEMBLY Page 195 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 9342 Front Fender Liner: Service and Repair Installation EXTERIOR: FENDER LINER (for Front Side): INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (a) for Steel Type Bumper: Install the front fender splash shield. (1) Install the fender splash shield with the 2 screws, clip and 2 new clips labeled A. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (b) for Resin Type Bumper: Install the front fender splash shield. (1) Install the fender splash shield with the 2 screws and 2 clips. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (2) Install the pin hold clip so that its groove is vertical. 2. INSTALL FENDER APRON MUDGUARD SEAL LH (a) for Steel Type Bumper: Install the fender apron mudguard seal. (1) Install the fender apron mudguard with the 3 clips and 15 new clips labeled A. Page 9120 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Components Actuator: Service and Repair Components DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): COMPONENTS Page 2042 Driver Side J/B Inner Circuit Components Refrigerant Pressure Sensor / Switch: Service and Repair Components AIR CONDITIONING: PRESSURE SWITCH: COMPONENTS Front Door Courtesy Switch Door Switch: Service and Repair Front Door Courtesy Switch Components LIGHTING: FRONT DOOR COURTESY SWITCH: COMPONENTS Page 7873 15. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY (a) Attach the 4 claws to install the duct. 16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY (a) Attach the 4 claws to install the nozzle. 17. INSTALL AIR CONDITIONING UNIT (a) Install the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Installation. Page 7191 (a) Install the bracket with the bolt. 7. INSTALL RADIATOR ASSEMBLY (a) Install the radiator assembly See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Installation. 8. ADD POWER STEERING FLUID 9. BLEED POWER STEERING FLUID See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 10. INSPECT FOR POWER STEERING FLUID LEAK Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. Page 5265 2. INSPECT PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 3 Joint Type) (a) Using a dial indicator, measure the intermediate shaft runout. Maximum runout: 0.61 mm (0.0240 in.) * If the intermediate shaft runout is more than the maximum, replace the propeller with center bearing shaft assembly. (b) Using a dial indicator, measure the propeller shaft runout. Maximum runout: 1.02 mm (0.0402 in.) * If the propeller shaft runout is more than the maximum, replace the propeller with center bearing shaft assembly. 3. INSPECT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Mount the propeller shaft in a vise. NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. (b) Inspect the spider bearing for wear or damage. (c) Using a dial indicator, measure the spider bearing axial play by turning the yoke of the flange while holding the shaft tightly. Maximum runout: 0.05 mm (0.00197 in.) * If the spider bearing axial play is more than the maximum, replace the spider bearing. Page 6528 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3074 "Case2" 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 9123 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 4934 NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L bracket of the cable faces the inside of the vehicle. (i) Connect the transmission control cable support with the nut. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) 2. INSTALL FRONT SEAT ASSEMBLY LH (a) for Manual Seat Type: Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. (b) for Power Seat Type: Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. (c) for Center Seat: Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation. (d) for Fold Down Seat: Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Installation. 3. ADJUST SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type) 4. INSPECT SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type) 5. INSTALL UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 6. INSTALL LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 7. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 8. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 9. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 10. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 11. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 12. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard Up to 11/2009 Brake Fluid Pressure Sensor/Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8876 (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 5. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 4936 Shift Cable: Service and Repair Transmission Control Cable (for Floor Shift Type) Components A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Floor Shift Type): COMPONENTS Page 6652 Installation OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION 1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply) (a) Attach the 2 claws to install the power outlet socket. 2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard) (a) Attach the 2 claws to install the power outlet socket cover. 3. INSTALL REAR POWER OUTLET SOCKET (for Standard) (a) Attach the claw to install the power outlet socket. 4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL Exhaust Pipe (Except Regular Cab Standard Deck) Exhaust Pipe: Service and Repair Exhaust Pipe (Except Regular Cab Standard Deck) Components 1UR-FE EXHAUST: EXHAUST PIPE (except Regular Cab Standard Deck): COMPONENTS Page 7921 Air Bag: Testing and Inspection Front Seat Side Airbag Assembly (except Fold Down Seat Type) SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold Down Seat Type): ON-VEHICLE INSPECTION 1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat with a new one: Cuts, minute cracks or marked discoloration on the front seatback around the front seat side airbag. 2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat side airbag with a new one: * Cuts, minute cracks or marked discoloration on the front seat side airbag. * Cracks or other damage to the wire harness or connector. CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow the correct procedure. Front Seat Side Airbag Assembly (for Fold Down Seat Type) SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold Down Seat Type): ON-VEHICLE INSPECTION 1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 8064 Impact Sensor: Testing and Inspection Front Airbag Sensor SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE INSPECTION 1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If the front airbag sensor has defects as mentioned below, replace it with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. 3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: * For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the front airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 7989 2. INSTALL FRONT SEATBACK COVER WITH PAD LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 3. INSTALL FRONT SEAT HEADREST ASSEMBLY LH (for Manual Seat) 4. INSTALL INNER FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 5. INSTALL FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 6. INSTALL RECLINING ADJUSTER RELEASE HANDLE LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 7. INSTALL VERTICAL SEAT ADJUSTER KNOB LH (for 8 Way Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 8. INSTALL VERTICAL ADJUSTING HANDLE LH (for 8 Way Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Install the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. 10. INSTALL FRONT SEATBACK COVER WITH PAD LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 11. INSTALL INNER FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 12. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH (for Power Seat) See: Seat Belt Systems/Seat Belt/Service and Repair/Removal and Replacement/Front Seat Inner Belt Assembly/Installation 13. INSTALL FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 14. INSTALL RECLINING POWER SEAT SWITCH KNOB LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 15. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly 16. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Install the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 17. PERFORM INITIALIZATION NOTICE: Some systems need initialization after reconnecting the cable to the negative battery terminal See: Testing and Inspection/Programming and Relearning Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold Down Seat Type): COMPONENTS Power Window Control System (w/ Jam Protection Function) Power Window Switch: Locations Power Window Control System (w/ Jam Protection Function) WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/ Jam Protection Function): PARTS LOCATION Page 1149 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 7690 (a) Using a 14 mm socket hexagon wrench, remove the cap from the modulator. (b) Remove the O-ring from the cap. (c) Using pliers, remove the cooler dryer. Air Conditioning System (for Automatic Air Conditioning System) Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 8112 between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 9. INSTALL FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): COMPONENTS Page 5999 Starter Relay: Testing and Inspection 1UR-FE STARTING: STARTER RELAY: ON-VEHICLE INSPECTION 1. REMOVE STARTER RELAY (ST) (a) Remove the engine room relay box cover. (b) Remove the starter relay from the engine room relay block. 2. INSPECT STARTER RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL STARTER RELAY Page 6072 Ignition Switch: Service and Repair Installation 1UR-FE STARTING: IGNITION SWITCH: INSTALLATION 1. INSTALL IGNITION SWITCH ASSEMBLY (a) Attach the 2 claws to install the ignition switch to the steering lock. 2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Reassembly 3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly 4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly 5. INSTALL STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation. (b) for Manual Tilt and Manual Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation. (c) for Power Tilt and Power Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 6781 Multiple Junction Connector: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 6282 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 6294 Driver Side J/B - Cowl Side Left Components Engine Control Module: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS Service Precautions Seat Belt: Service Precautions SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): PRECAUTION CAUTION: Replace the faulty parts of the seat belt systems (outer belt, inner belt, bolts, nuts, adjustable shoulder anchor, tether anchor hardware and other related parts). When inspecting a vehicle that was in a collision, be sure to check all of the seat belt systems regardless of whether or not the system was activated in the collision. Replace any damaged or malfunctioning systems. 1. RUNNING TEST (IN SAFE AREA) CAUTION: Conduct this test in a safe area. (a) Fasten the front seat belt. (b) Drive the vehicle at 16 km/h (10 mph) and firmly depress the brake pedal. Check that the belts lock and cannot be extended at this time. If a belt does not lock, replace the seat belt assembly See: Service and Repair/Removal and Replacement/Front Seat Outer Belt Assembly (for Regular Cab)/Removal. HINT Inspect a seat belt assembly before installing it See: Testing and Inspection/Front Seat Outer Belt Assembly (for Regular Cab) Page 1805 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Locations Brake Lamp Relay: Locations Engine Room R/B, J/B - Engine Compartment Left Page 668 Power Door Lock Switch: Testing and Inspection Unlock Warning Switch DOOR LOCK: UNLOCK WARNING SWITCH: INSPECTION 1. INSPECT UNLOCK WARNING SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the unlock warning switch assembly. Page 8627 Auxiliary Input / Output Jack: Service and Repair Stereo Jack Adapter Assembly (for Floor Shift Type) Components AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Floor Shift Type): COMPONENTS Page 7597 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 5329 Control Module: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION 1. INSTALL 4WD CONTROL ECU (a) Install the ECU with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. Page 963 Solar Sensor: Service and Repair Installation AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSTALLATION 1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Connect the connector. (b) Attach the 2 claws to install the sensor. 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. Page 5652 (c) Disconnect the connector (labeled D). (d) Remove the connector (labeled D) from the skid control sensor clamp (labeled H). (e) Remove the 2 bolts (labeled E) and 2 harness clamps (labeled F). (f) Remove the bolt (labeled G) and skid control sensor clamp (labeled H). 7. REMOVE FRONT SPEED SENSOR RH (a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the knuckle. 8. REMOVE FRONT SKID CONTROL SENSOR CLAMP RH (a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle. Installation BRAKE CONTROL: FRONT SPEED SENSOR: INSTALLATION 1. INSTALL FRONT SKID CONTROL SENSOR CLAMP LH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle. Page 5349 Transmission Speed Sensor: Testing and Inspection A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION 1. INSPECT SPEED SENSOR NT (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. 2. INSPECT SPEED SENSOR SP2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. Page 2685 Thermostat: Service and Repair Installation 1UR-FE COOLING: THERMOSTAT: INSTALLATION 1. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT (a) Install a new gasket and the water inlet with thermostat with the 3 nuts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. CONNECT OUTLET RADIATOR HOSE (a) Connect the radiator hose. HINT The direction of hose clamp is indicated in the illustration. 3. INSTALL AIR TUBE SUB-ASSEMBLY LH (a) Connect the air hose to the air switching valve LH, and install the air tube LH with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the vacuum sensor connector and clamp. (c) Connect the air tube LH to the water inlet housing with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the air hose. Page 6346 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 8359 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 3600 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSTALLATION 1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Install a new O-ring to the manifold absolute pressure sensor. (b) Install the manifold absolute pressure sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) (c) Connect the manifold absolute pressure sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 4028 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Locations Engine Temperature Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Airbag System Seat Occupant Sensor: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 9062 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 6520 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. Page 5403 Fluid - Transfer Case: Testing and Inspection JF1A TRANSFER: TRANSFER OIL: ON-VEHICLE INSPECTION 1. CHECK TRANSFER OIL (a) Remove the filler plug and gasket. (b) Check that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole. (c) If the result is not as specified, add transfer oil. Oil grade: GL-4 or GL-5 Viscosity: SAE 75W-90 Standard capacity: 1.1 +/- 0.06 liters (1.2 +/- 0.06 US qts, 1.0 +/- 0.05 Imp. qts) NOTICE: * After changing the oil, drive the vehicle and check the oil level again. * Too much or too little oil will lead to transfer problems. (d) When the oil level is too low, check for oil leak. (e) Install a new gasket into the filler plug and then tighten the plug. 2. ADD TRANSFER OIL (a) Remove the filler plug and gasket. (b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the case plug (for filler) hole. NOTICE: * When adding oil, pour it slowly. * Add oil a little at a time, waiting several minutes between each addition of oil. (c) Wait approximately 5 minutes and check that the oil level has not changed. (d) Install a new gasket and the filler plug. Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) Components Seat Memory Switch: Service and Repair Components SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): COMPONENTS Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 8839 (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 4. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY LH (a) Connect the speaker connector. (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 5. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Attach the 4 clips and claw to install the speaker panel. 6. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Page 9207 (e) Remove the inside handle. Reassembly ENGINE HOOD / DOOR: FRONT DOOR (for CrewMax): REASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Connect the 2 cables to the inside handle. (b) Connect the connector. (c) Attach the inside handle's knob to the door trim board. (d) Attach the 9 clips to install the door trim board. (e) Install the inside handle and door trim board to the door trim panel with the screw. (f) Install the door trim board to the door panel with the screw. (g) Install the clip. 2. INSTALL FRONT DOOR ARMREST COVER LH Locations Cabin Temperature Sensor / Switch: Locations AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 6992 Engine Room R/B, J/B - Engine Compartment Left Page 2153 Tire Pressure Sensor: Diagrams Page 6625 HINT Tape the screwdriver tip before use. 10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 5. INSTALL POWER OUTLET SOCKET ASSEMBLY Page 3087 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 4383 Fuel Pump Control Unit: Service and Repair Installation 1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION 1. INSTALL FUEL PUMP ECU (a) Install the fuel pump ECU with the 2 bolts. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being dropped, etc. (b) Connect the 2 fuel pump ECU connectors. Page 130 Compressor Clutch Relay: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Glass Breakage Sensor (for Floor Shift Type) Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Floor Shift Type) Components THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): COMPONENTS Removal THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH Page 4987 (c) If the result is not as specified, replace the solenoid valve. 6. INSPECT SHIFT SOLENOID VALVE SL2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. 7. INSPECT SHIFT SOLENOID VALVE SR Page 7682 Compressor Speed Sensor: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Locations Parking Assist Distance Sensor: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 7980 (b) Detach the 2 claws and disconnect the DLC3. (c) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. Installation SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY: INSTALLATION 1. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Attach the 2 claws to install the DLC3. (c) Install the 4 bolts to install the instrument panel airbag. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. CHECK SRS WARNING LIGHT Page 8844 (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): INSTALLATION 1. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY RH (a) Connect the speaker connector. (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 2. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY LH (a) Connect the speaker connector. (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 3. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Page 9022 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Components Seat Occupant Classification Module - Air Bag: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: COMPONENTS Page 6785 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 6055 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Components Steering Control Module: Service and Repair Components POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Page 6985 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 7172 Front Steering Knuckle: Service and Repair Installation AXLE: STEERING KNUCKLE: INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL KNUCKLE GREASE RETAINER CAP LH (for 2WD) (a) Using a brass bar and hammer, tap in a new retainer cap. NOTICE: * The retainer cap is a non-reusable part. * Do not damage the retainer cap. 2. INSTALL STEERING KNUCKLE OIL SEAL LH (a) Using SST and a press, press in a new oil seal. SST : 09950-60020 09951-01030 SST : 09950-70010 09951-07100 NOTICE: * The oil seal is a non-reusable part. * Do not damage the steering knuckle oil seal. 3. INSTALL STEERING KNUCKLE LH (a) Install the front suspension upper arm to the steering knuckle with the nut. Torque : 110 Nm (1,122 kgf-cm, 81 ft-lbf) (b) Install a new clip. HINT If the holes for the clip are not aligned, tighten the nut up to another 60. 4. CONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Suspension/Control Arm/Service and Repair/Removal and Replacement/Front Lower Suspension Arm/Installation 5. CONNECT TIE ROD END SUB-ASSEMBLY LH See: Steering Gear/Service and Repair/Removal and Replacement/Installation Page 3532 2. CHECK DLC3 (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NOTICE: When the measured value is higher than 132 Ohms and a CAN communication system DTC is output, there may be a problem besides disconnection of the DLC3 branch wire. For that reason, troubleshooting should be performed again from "HOW TO PROCEED WITH TROUBLESHOOTING" See: Initial Inspection and Diagnostic Overview/CAN Communication System after repairing the trouble area. NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step. 3. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 JUNCTION CONNECTOR - ECM) (a) Disconnect the J94 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CONNECT CONNECTOR OK -- Continue to next step. 4. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU) (a) Disconnect the J84 No. 1 junction connector connector. Page 9000 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 8105 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Page 5027 Page 2337 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 2194 Tire Pressure Monitor Receiver / Transponder: Diagrams Specifications Firing Order: Specifications Firing Order 1-8-4-3-6-5-7-2 Page 6006 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 297 Driver Side J/B - Cowl Side Left Page 3063 Page 1051 Page 5195 (h) Using a brass bar and hammer, tap out the inner race. NOTICE: Be careful not to damage the inner race. (i) Remove the cage. 4. REMOVE INBOARD JOINT BOOT (a) Remove the inboard joint boot from the outboard joint shaft. 5. REMOVE OUTBOARD JOINT BOOT CLAMP (a) Using a side cutter, cut the 2 outboard joint boot clamps and remove them. 6. REMOVE OUTBOARD JOINT BOOT (a) Remove the outboard joint boot from the outboard joint shaft. 7. REMOVE FRONT DRIVE SHAFT DUST COVER LH (a) Using SST and a press, press out the dust cover. SST : 09950-00020 8. REMOVE DUST SEAL (a) Using SST and a press, press out the dust seal. Page 8801 4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 5. REMOVE FRONT DOOR ARMREST COVER LH 6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 4 screws and speaker. NOTICE: Do not touch the cone part of the speaker. 9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) (a) Remove the 3 screws and speaker with bracket. (b) Detach the 3 claws and remove the speaker from the bracket. NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSTALLATION HINT * Use the same procedures for the LH side and RH side. Page 8831 (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 4. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY LH (a) Connect the speaker connector. (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 5. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Attach the 4 clips and claw to install the speaker panel. 6. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Page 7582 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 663 Power Door Lock Switch: Diagrams Unlock Warning Switch Page 6938 Driver Side J/B - Cowl Side Left Page 7808 Compressor Clutch Relay: Testing and Inspection AIR CONDITIONING: MAGNETIC CLUTCH RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAGNETIC CLUTCH RELAY (MG CLT) (a) Remove the magnetic clutch relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: * If the result is not as specified, replace the relay. (c) Install the magnetic clutch relay. Page 6042 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 7604 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 9222 Page 1096 Headlamp Dimmer Switch: Service and Repair Removal LIGHTING: HEADLIGHT DIMMER SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 7. REMOVE LOWER STEERING COLUMN COVER (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal 9. REMOVE LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 10. REMOVE UPPER STEERING COLUMN COVER (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 11. REMOVE UPPER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal 12. REMOVE UPPER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 13. REMOVE TILT AND TELESCOPIC MANUAL SWITCH (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 14. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal 15. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (a) Disconnect the connectors. Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Control Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 9129 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 1471 Ignition Switch: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 3692 ^ 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 3139 (3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. (4) Pinch the connector and disconnect the connector and pipe. (5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out. NOTICE: Do not use any tools. (6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. (7) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag. (e) Observe these precautions when connecting the fuel tube connector (for Quick Type). (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe. (3) After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected. Page 395 HINT The wavelength becomes shorter as the engine rpm increases. (f) WAVEFORM 5: HINT * The wavelength becomes shorter as the engine rpm increases. * The waveforms and amplitudes displayed differ slightly depending on the vehicle. (g) WAVEFORM 6: HINT The wavelength becomes shorter as engine rpm increases. (h) WAVEFORM 7: Page 7533 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Engine Controls - ECM Update For Shift Performance Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 1376 Impact Sensor: Diagrams Front Airbag Sensor Page 8284 Removal SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. REMOVE REAR SEAT ASSEMBLY (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 2. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal Diode (Front Door Courtesy Light) Diode: Diagrams Diode (Front Door Courtesy Light) Page 6969 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 5070 09954-03010 09955-03030 09956-03020 (b) Coat the threads of the nut with hypoid gear oil. (c) Using SST to hold the companion flange. SST : 09330-00021 09330-00030 (d) Tighten the nut until the standard preload is reached. Torque : 451 Nm (4599 kgf-cm, 332 ft-lb for less) NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. (e) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Standard preload (at starting): (f) If necessary, disassemble and inspect the differential assembly. 20. ADJUST BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (a) Using SST and a dial indicator, measure the ring gear backlash. SST : 09564-33010 Page 8249 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT SEAT ASSEMBLY (a) for Manual Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. (b) for Power Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 3. REMOVE FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Partially remove the front door opening trim weatherstrip so that the center lower pillar garnish and center pillar garnish can be removed See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. 6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP (a) Partially remove the rear door opening trim weatherstrip so that the center lower pillar garnish and center pillar garnish can be removed See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. 7. REMOVE LOWER CENTER PILLAR GARNISH (a) Detach the 2 claws and remove the cover. (b) Remove the bolt and seat belt anchor. Page 2512 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 3369 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 8201 1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET (a) Remove the 2 bolts and 2 anchor brackets. Installation SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Regular Cab): INSTALLATION 1. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET (a) Align the holes with the positioning pins and install the 2 anchor brackets with the 2 bolts. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 2729 (c) Connect the tailpipe to the center exhaust pipe. (d) Attach a new clamp to the tailpipe and center exhaust pipe. Then install the bolt to the clamp. Torque : 32 Nm (326 kgf-cm, 24 ft-lbf) HINT Install the clamp within the angle range shown in the illustration. 14. INSPECT FOR EXHAUST GAS LEAK See: Exhaust Manifold/Service and Repair/Installation Page 7190 (a) Install a new gasket to the pressure feed tube. (b) Install the pressure feed tube with the union bolt. Torque : 51 Nm (520 kgf-cm, 38 ft-lbf) 3. CONNECT SOLENOID VALVE CONNECTOR (a) Connect the solenoid valve connector. 4. CONNECT POWER STEERING OIL PRESSURE SENSOR CONNECTOR (a) Connect the oil pressure sensor connector. 5. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (a) Connect the hose with the clip. 6. CONNECT HARNESS BRACKET Page 6924 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Locations Door Switch: Locations DOOR LOCK: KEY REMINDER WARNING SYSTEM: PARTS LOCATION Page 2535 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Page 4688 Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch Page 9364 6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be used in their place 7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts (see Figures 8 and 9). Page 4938 Removal A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Floor Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 7. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE CONSOLE BOX CARPET 9. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 10. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 11. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY Page 6521 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Specifications Ball Joint: Specifications Ball Joints FRONT SUSPENSION UPPER ARM ASSEMBLY LH Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per 1 turn and take the torque reading on the fifth turn. Standard turning torque..........................................................................................................................0.98 to 4.41 N*m (1.0 to 45 kgf*cm, 9 to 39 in.*lbf) FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the fifth turn. Standard turning torque.........................................................................................................................3.0 to 10.0 N*m (31 to 102 kgf*cm, 27 to 89 in.*lbf) Page 454 Air Bag Control Module: Diagrams Page 7154 Tire Pressure Sensor: Service and Repair Disposal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire pressure warning valve and transmitter, remove the battery and dispose of it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Use the tip of a screwdriver to pry off the back cover. (b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that connect the battery to the base board. 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 6983 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 6263 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. Page 6207 (a) for AC Power Supply: Disconnect the clamp. (b) Remove the 4 screws and bezel. 5. REMOVE REAR POWER OUTLET SOCKET (for Standard) (a) Detach the claw and remove the power outlet socket. 6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard) (a) Detach the 2 claws and remove the power outlet socket cover. 7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply) (a) Detach the 2 claws and remove the power outlet socket. Page 5844 * The zero point calibration is performed only once after the system enters test mode. * Calibration cannot be performed again until the stored data is cleared once. (2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased. (3) Turn the ignition switch OFF. 4. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING SST CHECK WIRE) (a) Turn the ignition switch to ON. (b) Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more within 8 seconds. SST : 09843-18040 (c) Check that the SLIP indicator light comes on. (d) Using a check wire, perform the zero point calibration of the deceleration sensor. 5. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND DECELERATION SENSOR (WHEN USING SST CHECK WIRE) NOTICE: * While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it stationary. (Do not start the engine.) * While obtaining the zero point, do not depress the brake pedal. * Obtain the zero point on a level surface (with an inclination of 1° or less). (a) Enter Test Mode. (1) Turn the ignition switch off. (2) Check that the shift lever is in parking or neutral and apply the parking brake. CAUTION: Application of the parking brake is not necessary for entering test mode. However, apply the parking brake for safety. (3) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3. SST : 09843-18040 (4) Turn the ignition switch to ON. NOTICE: Do not start the engine. (b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor. Page 636 (a) Detach the 4 clips. (b) Disconnect the connector and remove the panel. 11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE (a) Detach the 2 claws and remove the sensor. Installation THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE (a) Attach the 2 claws to install the sensor. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY Locations Solar Sensor: Locations AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 3312 Engine Control Module: Locations Engine Compartment Page 1799 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 896 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Center Airbag Sensor Assembly (for Column Shift Type) Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 342 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 8496 Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation Page 1318 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 1112 Interior Light Switch: Service and Repair Installation LIGHTING: ROOM LIGHT SWITCH: INSTALLATION 1. INSTALL ROOM LIGHT SWITCH ASSEMBLY (a) Attach the 2 claws to install the light switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Power Source Control ECU Power Distribution Module: Diagrams Power Source Control ECU Page 7858 Evaporator Temperature Sensor / Switch: Testing and Inspection AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: INSPECTION 1. INSPECT NO. 1 COOLER THERMISTOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NOTICE: * Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. * When measuring, the sensor temperature must be almost the same as the ambient temperature. HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the sensor. Page 7644 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 6405 Rear Door Wire Rear Sonar Wire Page 3449 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU (CANH, CANL) OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal 18. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR) (a) Disconnect the J46 center airbag sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 3730 Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 3727 Page 675 (a) Using a moulding remover, detach the 2 clips and 5 claws, and remove the armrest base panel. (b) Disconnect the door control switch connector and power window regulator connector. 2. REMOVE DOOR CONTROL SWITCH ASSEMBLY (a) Detach the 2 claws and remove the door control switch. Installation DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): INSTALLATION 1. INSTALL DOOR CONTROL SWITCH ASSEMBLY (a) Attach the 2 claws to install the control switch. 2. INSTALL FRONT ARMREST UPPER BASE PANEL RH (a) Connect the door control switch connector and power window regulator connector. Page 8409 Page 2198 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Install the receiver with the bolt. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the receiver connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 4660 Transfer Case Actuator: Diagrams Page 8629 Remove the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 10. REMOVE CONSOLE BOX CARPET 11. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 12. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 13. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 14. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 15. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 16. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 17. REMOVE STEREO JACK ADAPTER ASSEMBLY (a) Detach the 2 claws and remove the adapter. Installation Page 3996 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 1555 No further tightening is required once the nut is tightened with the specified torque. 2. INSTALL WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 3. INSPECT TIRE (a) Inspect the tire See: Maintenance/Wheels and Tires/Testing and Inspection/Component Tests and General Diagnostics. 4. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration. 5. PERFORM INITIALIZATION (a) Perform initialization See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 6. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 5796 Hydraulic Fluid Regulator: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 4369 Fuel Pressure: Testing and Inspection 1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. NOTICE: Do not start the engine. (c) Turn the Techstream main switch ON. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (e) Check the fuel pump operation. (1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard. If there is no sound, check the integration relay, fuel pump, ECM and wiring connector. (f) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. 2. CHECK FUEL PRESSURE (a) Check that the battery voltage is 11 to 14 V. (b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Service Precautions. (c) Disconnect the cable from the negative (-) battery terminal. (d) Remove the fuel pipe clamp from the fuel tube connector. (e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it. CAUTION: * Always read the precautions See: Service Precautions before disconnecting the fuel tube connector (quick type). * The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. (f) Install SST (pressure gauge) as shown in the illustration. Page 3515 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU (CANH, CANL) OK -- REPLACE 4WD CONTROL ECU 26. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (ECM) (a) Disconnect the A24 ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Result E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL) D -- REPLACE ECM Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 1719 Standard steering axis inclination (unloaded vehicle): for CrewMax of standard deck Page 6802 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 6350 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 8190 Seat Occupant Classification Module - Air Bag: Service and Repair Installation SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: INSTALLATION 1. INSTALL OCCUPANT CLASSIFICATION ECU (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Attach the claw and install the occupant classification ECU to the seat. NOTICE: * If the ECU has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the ECU, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the ECU. 2. INSTALL FRONT SEAT ASSEMBLY RH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. Page 6372 Page 4137 Page 3540 2. CHECK FOR OPEN IN CAN BUS WIRE (CENTER AIRBAG SENSOR BRANCH WIRE) (a) Disconnect the J46 center airbag sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CENTER AIRBAG SENSOR BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (CENTER AIRBAG SENSOR - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 4919 6. INSTALL COLUMN SHIFT SHIFT LOCK RELEASE LINK (a) Install the spring and shift lock release link to the shift lever plate. 7. INSTALL SHIFT LEVER PLATE SUB-ASSEMBLY (a) Install the shift lever plate to the column shift control shift lever retainer with the 3 bolts. Torque : 2.3 Nm (23 kgf-cm, 20 in-lbf) (b) Secure the harness with 4 new wire guides and the wire harness clamp as shown in the illustration. Page 6818 Page 5762 28. REMOVE REAR WHEEL RH 29. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY RH HINT Use the same procedures described for the LH side. 30. REMOVE REAR DISC RH HINT Use the same procedures described for the LH side. 31. REMOVE PARKING BRAKE SHOE RETURN SPRING RH HINT Use the same procedures described for the LH side. 32. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY RH HINT Use the same procedures described for the LH side. 33. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY RH HINT Use the same procedures described for the LH side. 34. REMOVE PARKING BRAKE SHOE LEVER RH HINT Use the same procedures described for the LH side. 35. REMOVE NO. 2 PARKING BRAKE CABLE ASSEMBLY (a) Disconnect the No. 2 parking brake cable from the 2 clamps (labeled A). (b) Remove the 5 bolts (labeled B) and disconnect the No. 2 parking brake cable from the intermediate lever (labeled C). NOTICE: Do not bend and twist the parking brake cable. (c) Remove the bolt (labeled D) and clamp. Components Evaporative Emission Control Canister: Service and Repair Components 1UR-FE EMISSION CONTROL: CANISTER: COMPONENTS Page 1715 Standard caster inclination (unloaded vehicle): for CrewMax of standard deck Page 3076 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 7023 for Double Cab of Long Deck for CrewMax of standard deck Page 6155 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Diagrams Steering Angle Sensor: Diagrams Page 1153 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Diagrams Variable Valve Timing Actuator Position Sensor: Diagrams Page 8160 Air Bag Control Module: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 1879 (b) Remove the oil filter drain plug. (c) Install the pipe to the oil filter cap. HINT Use a container to catch the draining oil. NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe. (d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as shown in the illustration. (e) Using SST, remove the oil filter cap. SST : 09228-06501 NOTICE: Do not remove the oil filter bracket clip. Page 3459 (a) Disconnect the J28 combination meter ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE COMBINATION METER ASSEMBLY ECM Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: ECM Communication Stop Mode ECM Communication Stop Mode DESCRIPTION WIRING DIAGRAM Page 7475 Tire Pressure Module: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 6789 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 1776 Assenmacher Specialty Tools 1-800-525-2943 Locations Tilt Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Page 6959 Locations Tire Pressure Sensor: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 3567 16. CHECK OUTER MIRROR CONTROL ECU HINT For vehicles with a front power seat control system (w/ Seat Memory) only. (a) Disconnect the N7 and N8 ECU connectors. (b) Measure the resistance according to the value(s) in the table below. 17. CHECK MULTIPLEX TILT AND TELESCOPIC ECU HINT For vehicles with a front power seat control system (w/ Seat Memory) only. (a) Disconnect the J47 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Page 1154 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 6558 Relay Box: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Page 6972 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1639 (c) for CrewMax: (1) Remove the power window regulator master switch See: Service and Repair/Power Window Master Switch/Removal. (2) Reconnect the switch connector. (3) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 5040 * Align the holes for the straight pin in the differential case and pinion shaft. * Apply hypoid gear oil to each sliding surface and rotating part. (c) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case. Standard backlash: 0.05 to 0.20 mm (0.00197 to 0.00788 in.) (c) If the backlash is not within the specified value, replace the side gear thrust washer with an appropriate thickness. HINT Refer to the following table to select thrust washers which will ensure that the backlash is within the specified value. Washer thickness: (d) Using a pin punch and hammer, tap the straight pin through the holes in the differential case and pinion shaft. (e) Using a chisel and hammer, stake the outside of the differential case pin hole. 4. INSTALL REAR DIFFERENTIAL CASE BEARING (a) Using SST and a press, press in the 2 bearings. SST : 09710-30050 SST : 09950-60010 09951-00480 SST : 09950-70010 09951-07150 Page 8414 Seat Position Sensor: Service and Repair Installation SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: INSTALLATION 1. INSTALL SEAT POSITION SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning (c) Using a feeler gauge 1.0 mm (0.0393 in.), install the seat position sensor. NOTICE: * If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the seat position sensor with a new one. * When installing the seat position sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. HINT Be sure that the clearance between the seat position sensor and the seat rail is within 0.6 to 1.4 mm (0.0236 to 0.0551 in.). (d) Using a T30 "TORX" socket wrench, install the seat position sensor with the screw. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (e) Make sure that the clearance between the seat position sensor and the seat rail is within 0.6 to 1.4 mm (0.0236 to 0.0551 in.). (f) Check that there is no looseness in the installation parts of the seat position sensor. (g) Connect the connector. (h) Install the seat slide position sensor protector to the seat position sensor. Page 7544 * The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and Repair/Removal and Replacement/Removal 3. REMOVE FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Front Brake/Removal 4. REMOVE FRONT AXLE LH HUB BOLT (a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the front axle hub bolt. SST : 09650-17011 NOTICE: Do not damage the threads of the hub bolts. 5. INSTALL FRONT AXLE LH HUB BOLT (a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration. NOTICE: Install hub nuts to prevent damage to the hub bolts. (b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of the hub bolt head touches the axle hub. (c) Remove the washer and hub nut. NOTICE: Do not damage the threads of the hub bolts. 6. INSTALL FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Front Brake/Installation 7. CONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and Repair/Removal and Replacement/Installation 8. INSTALL FRONT WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) Page 5434 2. REMOVE PROPELLER SHAFT ASSEMBLY (for 2 Joint Type) See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Removal 3. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type) See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Removal 4. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and Repair/Overhaul/Disassembly 5. REMOVE TRANSFER CASE REAR OIL SEAL (a) Using SST, tap out the oil seal. SST : 09308-00010 NOTICE: Do not damage the oil-seal-fitted surface of the rear extension housing. 6. INSTALL TRANSFER CASE REAR OIL SEAL (a) Apply transfer oil to the spline area of the output shaft. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the housing upper surface. SST : 09316-60011 09316-00011 7. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and Repair/Overhaul/Reassembly 8. INSTALL PROPELLER SHAFT ASSEMBLY (for 2 Joint Type) See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Installation 9. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type) See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Installation 10. ADD TRANSFER OIL See: Fluid - Transfer Case/Service and Repair 11. CHECK TRANSFER OIL See: Fluid - Transfer Case/Testing and Inspection 12. CHECK FOR TRANSFER OIL LEAK Page 3917 (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 3222 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. Page 2235 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 4193 Page 6588 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 6396 Page 5971 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 6018 Torque : 43 Nm (438 kgf-cm, 32 ft-lbf) (b) Install the harness bracket to the generator with the bolt. Torque : 31 Nm (316 kgf-cm, 23 ft-lbf) (c) Connect the generator connector. (d) Connect the generator wire with the nut. Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) (e) Install the terminal cap. 2. CONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ Trailer Towing System) See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 3. CONNECT VANE PUMP ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Installation 4. CONNECT SOLENOID VALVE CONNECTOR See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Removal and Replacement/Installation 5. CONNECT POWER STEERING OIL PRESSURE SWITCH CONNECTOR See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Removal and Replacement/Installation 6. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 7. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Installation 8. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 4433 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection Page 3409 Components Tire Pressure Warning Reset Switch: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS Page 7002 Relay Box: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Page 9205 NOTICE: w/ Jam Protection Function: When disconnecting the cable, some systems need to be initialized after the cable is reconnected See: Windows and Glass/Windows/Testing and Inspection/Programming and Relearning/Initialization 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel. HINT Tape the screwdriver tip before use. 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (a) Using a screwdriver, detach the 2 clips and front upper armrest base panel. HINT Tape the screwdriver tip before use. (b) Disconnect the connectors. 4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Remove the 3 screws and power window regulator master switch. 5. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (a) Detach the 3 clips and remove the front lower door frame bracket garnish. Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 5291 (g) Using needle-nose pliers, install new snap rings into the grooves of the yoke. 2. INSPECT FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING See: Testing and Inspection/Component Tests and General Diagnostics/Front Propeller Shaft Assembly 3. INSPECT FRONT PROPELLER SHAFT ASSEMBLY HINT When replacing the spider bearing, make sure that the grease fitting assembly hole is facing in the direction shown in the illustration. Disassembly PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): DISASSEMBLY 1. REMOVE REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (for 3 Joint Type) (a) Place matchmarks on the propeller shaft yoke and universal joint yoke. (b) Remove the grease fitting from the spider bearing. Page 4036 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 7899 Solar Sensor: Service and Repair Installation AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSTALLATION 1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Connect the connector. (b) Attach the 2 claws to install the sensor. 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. Page 3235 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 6262 Fuse Block: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 3647 Page 6687 Page 9302 Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT TIMING GEAR LH Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) RH Using a wrench to hold the hexagonal portion of the No. 1 camshaft, tighten the camshaft timing gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) Page 4307 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 4652 Actuator: Service and Repair Installation DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): INSTALLATION 1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator. (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the differential tube as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent HINT Install the actuator within 10 minutes of applying seal packing. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the actuator onto the differential tube. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (g) Install the 4 bolts. Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) (h) Connect the actuator hose. (i) Connect the actuator connector. 2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Inspect the automatic disconnecting differential actuator See: Transmission and Drivetrain/Transfer Case/Testing and Inspection/Component Tests and General Diagnostics/Touch Select 2-4 and High-Low System. Page 5993 (g) Hold the switch in position and tighten the bolt. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (h) Using a screwdriver, bend the tabs of the lock washer. (i) Install the transmission control shaft lever RH with the spring washer and nut. Torque : 16 Nm (160 kgf-cm, 12 ft-lbf) (j) Connect the switch connector. 2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the cable with the nut. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L bracket of the cable faces the inside of the vehicle. 3. ADJUST SHIFT LEVER POSITION (for Column Shift Type) See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type) 4. ADJUST SHIFT LEVER POSITION (for Floor Shift Type) See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type) Components Condenser HVAC: Service and Repair Components AIR CONDITIONING: CONDENSER: COMPONENTS Page 7015 Auxiliary Power Outlet Switch: Service and Repair Installation OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION 1. INSTALL INVERTER MAIN SWITCH (a) Attach the 2 claws to install the main switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 6297 J/B No.4 - Instrument Panel Center Page 7868 (c) Install the 6 screws and attach the 4 claws. (d) Install the packing. 3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Install the heater radiator unit. (b) Attach the 3 claws to install the heater clamp. (c) Install the plate with the 3 screws. Locations Tire Pressure Monitor Receiver / Transponder: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 1396 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Page 5657 Wheel Speed Sensor: Service and Repair Rear Speed Sensor Components BRAKE CONTROL: REAR SPEED SENSOR: COMPONENTS Removal BRAKE CONTROL: REAR SPEED SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 7060 (d) * for 5 leaf spring Standard steering axis inclination (unloaded vehicle): for Regular Cab of Standard Deck Page 7961 HINT When scrapping a vehicle equipped with the SRS or disposing of the curtain shield airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a curtain shield airbag that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the curtain shield airbag. * The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag. * Do not apply water to a curtain shield airbag with a deployed airbag. * Always wash your hands with water after completing the operation. * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the roof headlining (for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal (e) Install SST. (1) Disconnect the connector from the curtain shield airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) After connecting SST each other, connect them to the curtain shield airbag. Page 6692 Page 2002 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 329 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 6474 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 6650 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL 1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL Page 2147 Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL 1. REMOVE ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Disconnect the receiver connector. (b) Remove the bolt and receiver. Page 6479 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 9225 Disassembly ENGINE HOOD / DOOR: FRONT DOOR (for Regular Cab): DISASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt Page 723 Removal SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE VERTICAL ADJUSTING HANDLE LH (for 8 Way Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 3. REMOVE VERTICAL SEAT ADJUSTER KNOB LH (for 8 Way Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 4. REMOVE RECLINING ADJUSTER RELEASE HANDLE LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 5. REMOVE FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 6. REMOVE FRONT POWER SEAT LUMBAR SWITCH LH (a) Remove the 2 screws and switch. Installation Page 7324 2. INSTALL FRONT NO. 2 LOWER ARM LH (a) Using SST and a press, press in a new bush. SST : 09710-26011 09710-05081 NOTICE: Press the bush while making sure the bush positioning protrusions are perpendicular to the lower arm, as shown in the illustration. 3. INSTALL FRONT NO. 1 LOWER ARM BUSH LH (a) Using SST and a press, press in a new bush. SST : 09223-00010 SST : 09612-30012 4. INSTALL FRONT LOWER BALL JOINT ATTACHMENT LH (a) Install the attachment with the nut and a new cotter pin. Torque : 167 Nm (1703 kgf-cm, 123 ft-lbf) NOTICE: Page 4323 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Air Fuel Ratio Sensor Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS Page 8833 Locations Fuse Block: Locations Engine Compartment Page 8189 Seat Occupant Classification Module - Air Bag: Service and Repair Removal SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY RH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE OCCUPANT CLASSIFICATION ECU (a) Disconnect the connector. (b) Detach the claw and remove the ECU from the seat. Page 1315 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 5572 Acceleration/Deceleration Sensor: Service and Repair Removal BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal 3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE YAW RATE SENSOR (a) Remove the 2 nuts (labeled A) and sensor. (b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the sensor bracket. Page 3292 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 4363 Fuel Pressure Regulator: Service and Repair Installation 1UR-FE FUEL: FUEL PRESSURE REGULATOR: INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY (a) Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the pressure regulator. NOTICE: * Make sure that there are no scratches or foreign matter in or around the insertion hole of the delivery pipe. * When inserting the pressure regulator, be careful not to damage the O-ring. (b) While turning the pressure regulator left and right, install it to the delivery pipe. (c) Install the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the vacuum sensing hose to the pressure regulator. (e) Connect the No. 2 fuel tube to the pressure regulator See: Service Precautions. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 9108 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 1454 Seat Position Sensor: Testing and Inspection SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: ON-VEHICLE INSPECTION 1. CHECK SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If there are any defects as mentioned below, replace the seat position sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. CAUTION: For removal and installation procedures of the seat position sensor, be sure to follow the correct procedure. Page 1846 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 6760 AJ9-JI2 Page 3957 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 5152 SST : 09502-12010 SST : 09316-60011 09316-00041 Standard oil seal depth: 5.6 to 6.6 mm (0.221 to 0.260 in.) (b) Coat the lip of the oil seal with MP grease. 20. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 21. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 22. INSPECT TOTAL PRELOAD See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 23. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 24. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 25. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 26. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Install the front differential carrier See: Differential Carrier/Service and Repair/Removal and Replacement/Front Differential Carrier Assembly/Installation. 27. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair Page 6734 Fuse Block: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 4912 Shifter A/T: Overhaul Disassembly A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): DISASSEMBLY 1. REMOVE COLUMN SHIFT SHIFTING BELLCRANK ASSEMBLY (a) Remove the bolt and shifting bellcrank from the column shift control shift lever retainer. 2. REMOVE COLUMN SHIFT LEVER COMPRESSION SPRING (a) Remove the bolt and spring from the column shift control shift lever retainer. 3. REMOVE SHIFT LEVER PLATE SUB-ASSEMBLY (a) Disconnect the transmission control switch connector clamp from the column shift. (b) Detach the wire harness clamp and cut off the 4 wire guides. (c) Remove the 3 bolts. Page 6559 Engine Room R/B And Engine Room J/B Inner Circuit Page 7281 Use the same procedures described for the LH side. 7. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Using a union nut wrench, disconnect the pressure feed tube (return tube side) from the power steering gear. (b) Using a union nut wrench, disconnect the pressure feed tube (pressure feed tube side) from the power steering gear. (c) Remove the 2 bolts and disconnect the pressure feed tube clamp. 8. REMOVE POWER STEERING GEAR ASSEMBLY (a) Remove the 2 bolts, 2 nuts and power steering gear. NOTICE: Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut fixed. Installation Diagrams Steering Mounted Controls Transmitter: Diagrams Components Acceleration/Deceleration Sensor: Service and Repair Components BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS Page 1280 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5765 Parking Brake Cable: Service and Repair Installation PARKING BRAKE: PARKING BRAKE CABLE: INSTALLATION 1. INSTALL NO. 2 CABLE SUPPORT BRACKET (a) Install the bracket with the 2 bolts. Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) 2. INSTALL PARKING BRAKE INTERMEDIATE LEVER SUB-ASSEMBLY (a) Apply MP grease to the moving parts of the intermediate lever. (b) Apply MP grease to the areas where the cables contact the intermediate lever. (c) Install the intermediate lever to the bracket with the clip, washer and pin. (d) Install the intermediate lever with bracket with the 2 bolts. Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) 3. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Install the No. 3 parking brake cable to the rear axle carrier with the bolt. Page 4453 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 2273 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 6950 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Removal and Replacement Steering Gear: Removal and Replacement Components POWER STEERING: STEERING GEAR: COMPONENTS Page 6163 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 6500 Junction Connector (CAN No.2) - Lower Finish Panel Page 7459 Tire Pressure Warning Reset Switch: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING RESET SWITCH (a) Disconnect the switch connector. (b) Detach the 2 claws and remove the reset switch. Specifications Connecting Rod: Specifications PISTON AND CONNECTING ROD The connecting rod cap bolts are tightened in 2 progressive steps. Step 1 Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque.................................................................................................................................................. .....................................40 Nm (408 kgf-cm, 30 ft-lbf) Step 2 Mark the front side of each connecting rod cap bolt with paint. Tighten the cap bolts another 90° as shown in the illustration in the order in step 1. Check that the painted marks are now at a 90° angle to the front. CONNECTING ROD SIDE CLEARANCE, OUT-OF-ROUND, & DIAMETER Page 940 (c) Install the 6 screws and attach the 4 claws. (d) Install the packing. 3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Install the heater radiator unit. (b) Attach the 3 claws to install the heater clamp. (c) Install the plate with the 3 screws. Page 2013 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Locations Engine Temperature Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6492 Engine Room R/B, J/B - Engine Compartment Left Page 8256 9. REMOVE FRONT SEAT OUTER BELT ASSEMBLY (a) Using a screwdriver, detach the 2 claws and open the seat belt anchor cover as shown in the illustration. HINT Tape the screwdriver tip before use. (b) Remove the bolt and disconnect the seat belt's shoulder anchor. (c) Disconnect the pretensioner connector as shown in the illustration. (d) Remove the 2 bolts and seat belt. Installation SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT SEAT OUTER BELT ASSEMBLY Page 4512 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 8803 Repair/Front Door (for CrewMax)/Reassembly 8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 9076 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 8761 Remote Switch: Testing and Inspection AUDIO / VISUAL: STEERING PAD SWITCH: INSPECTION 1. INSPECT STEERING PAD SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the steering pad switch assembly. Page 4783 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 4133 Page 392 Page 930 Evaporator Temperature Sensor / Switch: Testing and Inspection AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: INSPECTION 1. INSPECT NO. 1 COOLER THERMISTOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NOTICE: * Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. * When measuring, the sensor temperature must be almost the same as the ambient temperature. HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the sensor. Page 4013 (b) Remove the 2 bolts. (c) Remove the 3 bolts, air switching valve and gasket. NOTICE: Be careful not to damage the installation surface of the gaskets. Installation 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): INSTALLATION 1. INSTALL AIR SWITCHING VALVE ASSEMBLY (a) Install a new gasket and the air switching valve with the 3 bolts. Torque : 24 Nm (245 kgf-cm, 18 ft-lbf) NOTICE: Make sure the gasket's claws are not caught between the air switching valve and No. 4 air tube. (b) Install the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (c) Connect the wire harness clamp bracket with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) 2. CONNECT NO. 2 AIR HOSE (a) Align the paint mark with the projection and connect the No. 2 air hose. Page 6883 Power Distribution Module: Diagrams Voltage Inverter Diagrams Seat Belt Tensioner: Diagrams Page 566 Page 249 Power Distribution Relay: Diagrams Page 5769 Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) (b) Install the No. 1 parking brake cable to the inside of the vehicle with the 2 bolts (labeled B). Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the clamp (labeled C) to the No. 1 parking brake cable. (d) Install the clamp with the nut (labeled D). Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (e) Install the No. 1 parking brake cable and cable retainer with the bolt (labeled E). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) (f) Temporarily install the adjustment nut and lock nut (labeled F). NOTICE: Do not bend and twist the parking brake cable. HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE PEDAL TRAVEL" procedure. 26. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3700 mm [12 ft. 1.7 in.] Wheelbase Type) (a) Install the No. 1 cable support bracket with the 3 bolts (labeled A). Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) (b) Install the No. 1 parking brake cable to the inside of the vehicle with the 2 bolts (labeled B). Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the 2 clamps (labeled C) to the No. 1 parking brake cable. (d) Install the 2 clamps with the 2 nuts (labeled D). Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) Page 4324 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 2254 Wheel Fastener: Service and Repair Rear Axle Hub Bolt Components AXLE: REAR AXLE HUB BOLT: COMPONENTS Replacement AXLE: REAR AXLE HUB BOLT: REPLACEMENT HINT * Use the same procedures for the LH side and RH side. Audio and Visual System Remote Switch: Locations Audio and Visual System AUDIO / VISUAL: AUDIO AND VISUAL SYSTEM: PARTS LOCATION Locations Actuator: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 495 EFI Relay Fuel Pump Relay: Testing and Inspection EFI Relay 1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (EFI) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the EFI No. 1 fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the EFI No. 1 fuse. (b) Measure the resistance of the EFI relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 4898 Shifter A/T: Adjustments SHIFT LEVER ASSEMBLY (for Floor Shift Type) A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When moving the shift lever from N to other positions, check that the lever can be moved smoothly and accurately to each position and that the position indicator comes on in accordance with the shift lever position. If the indicator and shift lever position do not match, carry out the following adjustment procedures. 2. ADJUST SHIFT LEVER POSITION (a) Move the shift lever to N. (b) Fold back the transmission control cable adjust case cover. Then while sliding the slider toward the cable end side, press out the lock piece from the back side to release the lock. (c) Check that the spring of the adjust case is applying enough tension to the shift control cable. Then press in the lock piece to set the lock. NOTICE: * Use your hand to push in the lock piece. Do not use any tools. * Securely push in the lock piece so that the protrusion of the slider is above the lock piece. (d) Return the cover of the adjust case to its original position. (e) Inspect the shift lever operation after the adjustment. Page 9306 properly. Make sure to thoroughly wipe off the double-sided tape. 3. After cleaning the installation area of the body with degreasing agent, attach the name plate to the position shown in the illustration. HINT: 1. The working environment should be 20 degrees C when installing the name plate. If the working environment is below 20 degrees C, heat the installation area of the body to 20 to 30 degrees C and then install the name plate. Page 3066 Page 7170 Front Steering Knuckle: Service and Repair Removal AXLE: STEERING KNUCKLE: REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT AXLE HUB SUB-ASSEMBLY LH (a) Remove the front axle hub See: Suspension/Wheel Hub/Service and Repair/Removal and Replacement/Removal. 3. DISCONNECT FRONT SPEED SENSOR LH (a) Remove the clip and bolt. (b) Disconnect the speed sensor from the steering knuckle. 4. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (a) Remove the cotter pin and nut. (b) Using SST, disconnect the tie rod end LH from the steering knuckle. SST : 09610-20012 NOTICE: * Do not damage the front disc brake dust cover. * Do not damage the ball joint dust cover. * Do not damage the steering knuckle. 5. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Suspension/Control Arm/Service and Repair/Removal and Replacement/Front Lower Suspension Arm/Removal 6. REMOVE STEERING KNUCKLE LH (a) Support the front suspension lower arm LH with a jack. (b) Remove the clip and the nut. Page 2576 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Airbag Cut-OFF Switch Air Bag Deactivation Switch: Service and Repair Airbag Cut-OFF Switch Components SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Remove the lower No. 2 instrument panel airbag assembly See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal. 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE AIRBAG CUT-OFF SWITCH (a) Detach the 2 claws to remove the switch. Installation SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSTALLATION 1. INSTALL AIRBAG CUT-OFF SWITCH (a) Attach the 2 claws to install the switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Install the lower No. 2 instrument panel airbag assembly See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 7692 3. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (a) Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the air conditioning tube and accessory. (d) Connect the air conditioning tube and accessory on the cooler condenser with the 2 bolts. Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) NOTICE: * When tightening the bolt, do not allow any tools to contact the pipe. * When tightening the bolt, hold a part of the pipe near the connector. 4. CONNECT DISCHARGE HOSE (a) Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the discharge hose. Page 1402 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Page 6877 Accessory Relay: Diagrams Page 8235 Removal SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY (for Center Seat): REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (a) for Power Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. (b) for Manual Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Page 6613 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 4582 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. Page 5740 NOTICE: Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench See: Service Precautions 3. INSTALL BRAKE TUBE (a) Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench See: Service Precautions (b) Using a union nut wrench, connect the 2 brake tubes to the VSC actuator. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench See: Service Precautions 4. CONNECT VSC ACTUATOR CONNECTOR (a) Connect the VSC actuator connector. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding Audio System - Satellite Radio Inop. Until Key Is Cycled Radio Receiver: Customer Interest Audio System - Satellite Radio Inop. Until Key Is Cycled T-SB-0271-09 Rev1 August 11, 2009 XM Satellite Radio Inoperative Until Ignition Key Is Cycled Service Category Audio/Visual/Telematics Section Audio/Video Market USA Applicability March 30, 2010 Rev1: TSB REVISION NOTICE ^ Applicability has been updated to include additional 2010 - 2011 model year Toyota vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Some vehicles equipped with a PPO/DIO accessory XM Satellite Radio Receiver (P/N 86180-0W030 or 86180-0W031) may exhibit one or more of the following conditions: ^ XM Satellite Radio becomes non-operational or locked while in use. ^ Sound output becomes sporadic or non-existent. When either of these conditions occur cycling the ignition from "ON"-"OFF"-"ON" restores normal operation. Improved XM Satellite Radio Receiver exchange units are available to correct this condition. NOTE Page 6507 J/B No.6 Assembly Inner Circuit Locations Integrated Accessory Switch Assembly: Locations METER: METER / GAUGE SYSTEM: PARTS LOCATION Page 887 Oil Pressure Sender: Service and Repair Installation 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Apply adhesive to 2 or 3 threads of the oil pressure sender gauge. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (b) Install the oil pressure sender gauge. Torque : 15 Nm (153 kgf-cm, 11 ft-lbf) NOTICE: Do not start the engine within 1 hour after installation. (c) Connect the sender gauge connector. 2. INSPECT ENGINE OIL LEVEL See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Testing and Inspection 3. INSPECT FOR OIL LEAK See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 4. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 7401 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 8928 Integrated Accessory Switch Assembly: Diagrams Page 3081 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Components Cabin Temperature Sensor / Switch: Service and Repair Components AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): COMPONENTS Locations Shift Interlock Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 5991 Page 9275 Hood Shock / Support: Service and Repair Removal ENGINE HOOD / DOOR: HOOD SUPPORT: REMOVAL 1. REMOVE HOOD SUPPORT ASSEMBLY LH (a) Using a screwdriver, remove the hood support assembly while releasing the 2 clips. HINT Tape the screwdriver tip before use. CAUTION: Remove the hood support while supporting the hood by hand. 2. REMOVE NO. 1 HOOD SUPPORT BOLT (a) Remove the hood support bolt. CAUTION: Remove the hood support bolt while supporting the hood by hand. Page 4539 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Locations Lock Cylinder Switch: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 1335 Ignition Switch: Testing and Inspection 1UR-FE STARTING: IGNITION SWITCH: INSPECTION 1. INSPECT IGNITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the ignition switch assembly. Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. 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) Service and Repair Vehicle Lifting: Service and Repair INTRODUCTION: REPAIR INSTRUCTION: VEHICLE LIFT AND SUPPORT LOCATIONS 1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE (a) The vehicle must be unloaded before jacking up / lifting up the vehicle. Never jack up / lift up a heavily loaded vehicle. (b) When removing heavy parts such as the engine and transmission, the center of gravity of the vehicle may shift. To stabilize the vehicle, place a balance weight in a location where it will not roll or shift, or use a mission jack to hold the jacking support. 2. NOTICE FOR USING 4 POST LIFT (a) Follow the safety procedures outlined in the lift's instruction manual. (b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels. (c) Use wheel chocks to secure the vehicle. 3. NOTICE FOR USING JACK AND SAFETY STAND (a) Work on a level surface. Use wheel chocks at all times. (b) Use safety stands with rubber attachments as shown in the illustration. (c) Set the jack and safety stands to the specified locations of the vehicle accurately. (d) When jacking up the vehicle, first release the parking brake and move the shift lever to N. (e) When jacking up the entire vehicle: (1) When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels. (2) When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels. (f) When jacking up only the front or rear wheels of the vehicle: (1) Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels. (2) Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels. (g) When lowering a vehicle that only has its front or rear wheels jacked up: (1) Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels. (2) Before lowering the rear wheels, make sure wheel chocks are behind the front wheels. Testing and Inspection Wiring Harness: Testing and Inspection A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSPECTION 1. INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Measure the resistance according to the value(s) in the table below. HINT If the resistance is out of the specified range at any of the ATF temperatures shown in the table below, the driveability of the vehicle may decrease. Standard Resistance: (b) If the result is not as specified, replace the transmission wire. Page 4841 (b) When using the Techstream: Disconnect the Techstream from the DLC3. (c) w/ Trailer Towing System (with transmission oil thermostat): (1) Push in the shaft with a screwdriver and remove the pin. NOTICE: Make sure the shaft of the thermostat is protruding from the hole in the cap. (d) Inspect for automatic transmission fluid leaks. Page 1302 Page 2003 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 5927 Yaw Rate Sensor: Diagrams Locations Tire Pressure Warning Reset Switch: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 4003 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 7525 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 3283 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 8829 NOTICE: Do not touch the cone part of the speaker. 7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY RH (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. NOTICE: Do not touch the cone part of the speaker. 8. REMOVE NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Using a screwdriver, detach the 6 clips and 2 claws. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 9. REMOVE FRONT NO. 4 SPEAKER ASSEMBLY (for 12 Speakers) (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. A/T - World Standard Automatic Transmission Fluid Fluid - A/T: Technical Service Bulletins A/T - World Standard Automatic Transmission Fluid T-SB-0006-11 January 6, 2011 World Standard Automatic Transmission Fluid Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. TC010-07. Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. TSB No. TC010-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction World Standard (WS) Automatic Transmission Fluid (ATF) was introduced to reduce maintenance costs and increase the mileage between scheduled maintenance checks. Here are some important tips when working with ATF-WS in Toyota vehicles requiring its use. Warranty Information Page 362 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 5706 * Low pedal or spongy pedal. * Brake pedal is depressed firmly but braking is insufficient. (c) Check and adjust brake fluid level in reservoir See: Brake Fluid/Testing and Inspection. 2. BLEED BRAKE SYSTEM (a) Bleed brake master cylinder HINT If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder. (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Using a union nut wrench, disconnect the 2 brake lines from the master cylinder. (4) Slowly depress and hold the brake pedal. (5) Block the outer holes with your fingers, and release the pedal. (6) Repeat the 2 previous steps 3 or 4 times. (7) Using a union nut wrench, connect the 2 brake lines to the master cylinder. without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) with union nut wrench - Torque : 18 Nm (185 kgf-cm, 13 ft-lbf) * Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). * This torque value is effective when union nut wrench is parallel to the torque wrench. (b) Bleed brake line (1) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (3) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (4) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (5) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (6) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (7) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. Page 46 (a) Attach the 8 claws and 2 clips to install the scuff plate. 5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 2719 (a) Install the 4 No. 1 converter protector stays. (b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) HINT Install the monolithic converter protector within the angle range specified in the illustration. 3. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. (b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) HINT Install the monolithic converter protector within the angle range specified in the illustration. 4. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Install the 4 No. 1 converter protector stays. (b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) HINT Power Source Control ECU Power Distribution Module: Diagrams Power Source Control ECU Page 6673 Diode: Diagrams Diode (Starting) Locations Entertainment System Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 3457 Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (CENTER AIRBAG SENSOR BRANCH WIRE) (a) Disconnect the J46 center airbag sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CENTER AIRBAG SENSOR BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (CENTER AIRBAG SENSOR - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6743 J/B No.6 Assembly - Instrument Panel Center Page 2218 Tire Pressure Warning Reset Switch: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING RESET SWITCH (a) Attach the 2 claws to install the reset switch. (b) Connect the switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 8838 NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): INSTALLATION 1. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY (for 10 Speakers) (a) Connect the connector. (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 2. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Attach the 6 clips and 2 claws to install the speaker panel. 3. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY RH (a) Connect the speaker connector. Page 2185 Tire Pressure Module: Diagrams Page 1685 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 1853 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 2630 HINT The direction of hose clamp is indicated in the illustration. 5. CONNECT NO. 8 WATER BY-PASS HOSE (a) Connect the water by-pass hose. HINT The direction of hose clamp is indicated in the illustration. 6. INSTALL NO. 1 WATER BY-PASS HOSE (a) Install the water by-pass hose. HINT The direction of hose clamp is indicated in the illustration. 7. INSTALL WATER BY-PASS PIPE (w/ Oil Cooler) (a) Connect the 4 water hoses. HINT Connect each hose so that the direction of each hose clamp is as indicated in the illustration. (b) Install the water by-pass hose with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 4913 (d) Remove the shift lever plate from the column shift control shift lever retainer. 4. REMOVE COLUMN SHIFT SHIFT LOCK RELEASE LINK (a) Remove the shift lock release link and spring from the shift lever plate. 5. REMOVE COLUMN SHIFT SHIFT LEVER SUB-ASSEMBLY (a) Remove the shift lever and 2 lever selecting bushes from the column shift control shift lever retainer. (b) Using a thin-bladed screwdriver, release the connector housing retainer. Restraints - Seat Belt Extenders Seat Belt Extension: Technical Service Bulletins Restraints - Seat Belt Extenders T-SB-0053-09 Rev1 January 27, 2009 Seat Belt Extenders Service Category Vehicle Interior Section Seat Belt Market USA Applicability November 5,2009 Rev1: TSB REVISION NOTICE Applicability has been updated to include additional 2010 models. Any previous printed versions of this service bulletin should be discarded. Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. ^ The extender is available in 6-inch, 9-inch, 12-inch, 15-inch, and 18-inch lengths. ^ The extender is available only in black. ^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle. Page 2087 Driver Side J/B - Cowl Side Left Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 9249 Page 5277 4. TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type) (a) With the vehicle empty and all 4 tires supported by a lift, or with the vehicle suspension in the full rebound position, adjust the center bearing so that dimension A (the distance from the front surface of the center bearing housing to the back surface of the intermediate shaft) is as shown in the chart below. HINT Measure dimension A (the distance from the front surface of the center bearing housing to the back surface of the intermediate shaft) at 3 places and make adjustments so that the measured dimensions are equal. Standard dimension A: (b) Check that the center line of the bracket is at right angles to the shaft axial direction. (c) Tighten the 2 mounting bolts. Torque : 40 Nm (410 kgf-cm, 30 ft-lbf) 5. INSPECT PROPELLER SHAFT JOINT ANGLE (for 3 Joint Type) NOTICE: * Perform the inspection on a level surface. * Perform the inspection with the vehicle empty. * Perform the inspection with all wheels on the ground. (a) Measure the No. 1 joint angle. (1) Using SST, measure and record the angle of the intermediate shaft (C). SST : 09370-50010 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag(s) Arming and Disarming Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.) Page 5272 (a) Remove the 2 bolts and insulator bracket. 2. REMOVE TRANSFER HEAT INSULATOR (a) Remove the 3 bolts and heat insulator. 3. REMOVE PROPELLER SHAFT ASSEMBLY (for 2 Joint Type) (a) Place matchmarks on the propeller shaft flange and differential flange. (b) Remove the 4 nuts and 4 bolts, and disconnect the propeller shaft from differential side. (c) Place matchmarks on the propeller shaft flange and transfer flange. (d) Remove the 4 nuts and propeller shaft. 4. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type) Recall 10V091000: Front Driveshaft Replacement Drive/Propeller Shaft: All Technical Service Bulletins Recall 10V091000: Front Driveshaft Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Tundra 2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: March 09, 2010 NHTSA CAMPAIGN ID NUMBER: 10V091000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Axle Assembly: Axle Shaft POTENTIAL NUMBER OF UNITS AFFECTED: 2 SUMMARY: Toyota is recalling certain model year 2010 Tundra vehicles with four wheel drive, there is a possibility that an improper weld exists at the union of the propeller shaft and yoke. Due to this improper weld, this joint may separate and the separated shaft may come into contact with the road surface. CONSEQUENCE: This may result in a loss of vehicle control increasing the risk of a crash. REMEDY: Dealers will replace the front propeller shaft free of charge. The safety recall is expected to begin during March 2010. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Drivetrain - Front End Grinding Noise In 4WD Differential Mount: Customer Interest Drivetrain - Front End Grinding Noise In 4WD T-SB-0338-09 Rev1 September 16, 2009 Grinding Noise When in 4WD Service Category Drivetrain Section Axle/Differential Market USA Applicability March 10, 2010 Rev1: ^ Applicability has been updated to include 2008 - 2010 model year Sequoia vehicles. ^ Production Change Information has been added. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2008 - 2010 model year Sequoia and 2007 - 2010 model year Tundra vehicles may exhibit a grinding noise from the front of the vehicle while in 4WD. An updated differential support bolt is available to address this condition. Follow the repair procedure in this bulletin to inspect and replace the differential support bolt. 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 occurrence of the specified condition described in this bulletin. Page 8693 Integrated Accessory Switch Assembly: Service and Repair Removal METER: DRIVE MONITOR SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE DRIVE MONITOR SWITCH (a) Detach the 2 claws and remove the monitor switch. Page 398 HINT The wavelength becomes shorter as the engine rpm increases. (n) WAVEFORM 13: HINT The waveform varies depending on the CAN communication signal. (o) WAVEFORM 14: HINT The waveform varies depending on the CAN communication signal. (p) WAVEFORM 15: HINT The wavelength becomes shorter as the engine rpm increases. Page 4526 (4) Remove the 2 bolts and disconnect the water by-pass pipe. (5) Remove the 4 bolts and 4 ignition coils. 4. REMOVE SPARK PLUG (a) Using a 16 mm plug wrench, remove the 8 spark plugs. Specifications Timing Cover: Specifications TIMING CHAIN COVER SUB-ASSEMBLY Temporarily install the 26 bolts and nut. Standard Bolt: Tighten the 3 bolts in several steps in the sequence shown in the illustration. Torque.................................................................................................................................................. .....................................47 Nm (479 kgf-cm, 35 ft-lbf) Temporarily install the fan bracket with the 5 bolts. Standard Bolt: Temporarily install the belt tensioner with the bolt and 6 mm hexagon bolt. Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration. Page 5684 HINT Due to the inverse screw structure, if the stop light switch is turned clockwise, the stop light switch moves in the direction to be pulled out. (e) Connect the stop light switch connector. (f) Check the protrusion of the rod. Standard protrusion of the rod: 1.5 to 2.5 mm (0.0591 to 0.0984 in.) 3. CHECK PEDAL FREE PLAY (a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. (b) Push in the brake pedal until the beginning of the resistance is felt. Measure the distance as shown in the illustration. Standard pedal free play: 1.0 to 6.0 mm (0.0394 to 0.236 in.) 4. CHECK PEDAL RESERVE DISTANCE (a) Release the parking brake pedal. (b) With the engine running, depress the brake pedal and measure the pedal reserve distance as shown in the illustration. Standard pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 104 mm (4.09 in.) (c) If incorrect, troubleshoot the brake system See: Testing and Inspection. Page 2094 Junction Connector (CAN No.2) - Lower Finish Panel Page 3725 Engine Control Module: Pinout Values and Diagnostic Parameters 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM 1. CHECK ECM (a) Measure the voltage according to the value(s) in the table below. HINT The standard voltage between each pair of ECM terminals is shown in the table below. The appropriate conditions for checking each pair of terminals are also indicated. The result of checks should be compared with the standard voltage for that pair of terminals, displayed in the Specified Condition column. The illustration above can be used as a reference to identify the ECM terminal locations. Page 71 Double Cab)/Removal 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 6. REMOVE REAR DOOR SCUFF PLATE RH (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT The procedures listed below are for the LH side. 7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH 3. INSTALL REAR DOOR SCUFF PLATE RH (a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT The procedures listed below are for the LH side. 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1845 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 8042 Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable, Steering Pad Switch Page 4755 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 5970 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 3498 Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER) OK -Continue to next step. 20. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - BUS BUFFER ECU) NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU) OK -- Continue to next step. 21. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU) NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - ECM)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU) OK -- Continue to next step. 22. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - ECM) (a) Measure the resistance according to the value(s) in the table below. Page 9246 Page 2813 NG -- REPLACE RELAY OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 4. INSPECT ECM (IGSW VOLTAGE) (a) Disconnect the ECM connectors. (b) Turn the ignition switch to ON. (c) Measure the voltage according to the value(s) in the table below. Page 6503 Driver Side J/B Inner Circuit Up to 11/2009 Hose/Line HVAC: Service and Repair Up to 11/2009 AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS Page 8349 Impact Sensor: Service and Repair Side Airbag Sensor (for CrewMax) Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): COMPONENTS Page 8392 Seat Belt Buckle Switch: Diagrams Page 7588 Push the terminal retainer down to the temporary lock position. Page 7758 Removal AIR CONDITIONING: AIR CONDITIONING UNIT: REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair 2. DRAIN ENGINE COOLANT (a) for 1GR-FE: Climate Control Seat System Seat Heater Switch: Locations Climate Control Seat System SEAT: CLIMATE CONTROL SEAT SYSTEM: PARTS LOCATION Double Cab Power Mirror Control Module: Locations Double Cab Body Page 6092 5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Inspect the switch See: Testing and Inspection/Initial Inspection and Diagnostic Overview. Airbag System Seat Occupant Sensor: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Engine - Oil Filter Cap Assembly Precaution Oil Filter Housing: Technical Service Bulletins Engine - Oil Filter Cap Assembly Precaution T-SB-01 04-09 April 10, 2009 Oil Filter Cap Assembly Precautions Service Category Engine/Hybrid System Section Lubrication Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. T-SB-0332-08. ^ Applicability has been updated to include 2009 - 2010 model year Highlander, 2010 model year Camry, Corolla, Matrix, Sequoia, Tundra, and 2009 model year Venza vehicles. ^ The SST table has been updated with an illustration. ^ The Notice in the Repair Procedure has been updated with a Figure and torque specification ranges to clarify SST usage. TSB No. T-SB-0332-08 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction To prevent damage to the oil filter cap assembly this procedure must be closely followed during oil filter replacement to avoid immediate and future oil filter serviceability concerns. The following engines are equipped with a plastic oil filter cap assembly: ^ 1UR-FE (Tundra Sequoia) ^ 3UR-FE (Tundra Sequoia Land Cruiser) ^ 2ZR-FE (Corolla Matrix) Page 299 J/B No.4 - Instrument Panel Center Page 8299 5. Dealer places copy of the completed worksheet in the customer's records. Front Door Courtesy Switch Door Switch: Diagrams Front Door Courtesy Switch Page 8679 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 6332 Symbols Used Within Diagrams Symbols Used Within Diagrams Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 8347 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BATTERY (a) Disconnect the cable from the positive (+) battery terminal. (b) Loosen the nut, move the stay off the battery, and remove the battery. 3. REMOVE FRONT AIRBAG SENSOR (a) Remove the nut and front airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Connect the connector. (d) Install the front airbag sensor with the nut. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) Page 7028 *: for 5 leaf spring Standard Camber Inclination for Regular Cab of Standard Deck Page 4493 (3) When applying a vacuum to port F, check that air is sucked into port E. If the result is not as specified, replace the vacuum switching valve assembly. (e) Connect the vacuum switching valve connector. 3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 1820 ^ 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 Ignition Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 4420 Fuel Pump Control Unit: Locations Double Cab Body Page 2722 Exhaust Pipe: Service and Repair Exhaust Pipe (for Regular Cab Standard Deck) Components 1UR-FE EXHAUST: EXHAUST PIPE (for Regular Cab Standard Deck): COMPONENTS Page 4607 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 700 Power Seat Switch: Locations Front Power Seat Control System (w/o Memory) SEAT: FRONT POWER SEAT CONTROL SYSTEM (w/o Memory): PARTS LOCATION Page 8517 Page 7332 Front Steering Knuckle: Service and Repair Removal AXLE: STEERING KNUCKLE: REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT AXLE HUB SUB-ASSEMBLY LH (a) Remove the front axle hub See: Wheel Hub/Service and Repair/Removal and Replacement/Removal. 3. DISCONNECT FRONT SPEED SENSOR LH (a) Remove the clip and bolt. (b) Disconnect the speed sensor from the steering knuckle. 4. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (a) Remove the cotter pin and nut. (b) Using SST, disconnect the tie rod end LH from the steering knuckle. SST : 09610-20012 NOTICE: * Do not damage the front disc brake dust cover. * Do not damage the ball joint dust cover. * Do not damage the steering knuckle. 5. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Control Arm/Service and Repair/Removal and Replacement/Front Lower Suspension Arm/Removal 6. REMOVE STEERING KNUCKLE LH (a) Support the front suspension lower arm LH with a jack. (b) Remove the clip and the nut. Page 3585 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 6902 Page 8096 Page 9114 Push the terminal retainer down to the temporary lock position. Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Page 2053 Page 6609 Page 7913 Air Bag: Diagrams Front Passenger Side Squib Circuit Page 4594 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 6830 Locations Cargo Lamp Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 1291 Crankshaft Position Sensor: Diagrams Page 32 Central Control Module: Service and Repair Installation AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: INSTALLATION 1. INSTALL MULTI-DISPLAY CONTROLLER BRACKET A (a) Install the multi-display controller bracket A with the 2 bolts. Torque : 2.0 Nm (20 kgf-cm, 17 in-lbf) 2. INSTALL MULTI-MEDIA INTERFACE ECU (a) Connect the connector. (b) Install the multi-media interface ECU with the nut. Torque : 8.0 Nm (81 kgf-cm, 70 in-lbf) 3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 809 Page 6160 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 3911 Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the Techstream to the DLC3. (b) Start the engine and turn the tester ON. (c) Warm up the engine. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear (Bank 1) or Control the VVT Linear (Bank 2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2). (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK: (f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear. HINT * Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of bank 1 (Control range: Between -128 to 127%). * Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves of bank 2 (Control range: Between -128 to 127%). * Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range: ON/OFF). * Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range: ON/OFF). * Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of bank 1 (Control range: Between -128 to 127%). * Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of bank 2 (Control range: Between -128 to 127%). Page 6819 Page 9137 Connectors Part 1 Page 6951 J/B No.6 Assembly Inner Circuit Page 6293 Driver Side J/B - Cowl Side Left Specifications Harmonic Balancer - Crankshaft Pulley: Specifications CRANKSHAFT PULLEY Torque.................................................................................................................................................. ...............................300 Nm (3059 kgf-cm, 221 ft-lbf) Page 5196 SST : 09950-00020 Reassembly DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): REASSEMBLY NOTICE: Do not allow brake fluid, front differential oil, gasoline, or battery fluid to contact the drive shaft boots, as they may damage the boots. 1. INSTALL DUST SEAL (a) Using SST and a press, press in a new dust seal to the outboard joint shaft. SST : 09950-00020 NOTICE: Be careful not to damage the dust seal. 2. INSTALL FRONT DRIVE SHAFT DUST COVER LH (a) Using SST, a steel plate and press, press in a new dust cover. SST : 09316-20011 NOTICE: Be careful not to damage the dust cover. 3. INSTALL OUTBOARD JOINT BOOT (a) Place 2 new boot clamps on the boot. Page 2892 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6176 Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. See: Locations Page 8774 Speaker: Diagrams Center Speaker Front Door Speaker Page 7583 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 6387 Page 263 Page 5612 Steering Angle Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 2330 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Page 757 Sunroof / Moonroof Switch: Service and Repair Installation SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): INSTALLATION 1. INSTALL SLIDING ROOF SWITCH (a) Attach the 4 claws to install the sliding roof switch. (b) Install the lighting housing (upper side) with the 7 screws. (c) Attach the clamp. (d) Connect the 2 connectors. 2. INSTALL ROOF CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 7847 Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag(s) Arming and Disarming Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.) Page 673 2. INSTALL FRONT ARMREST UPPER BASE PANEL LH (a) Connect the power window regulator master switch connector. (b) Attach the 2 clips and 5 claws to install the armrest base panel. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 6091 (g) Hold the switch in position and tighten the bolt. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (h) Using a screwdriver, bend the tabs of the lock washer. (i) Install the transmission control shaft lever RH with the spring washer and nut. Torque : 16 Nm (160 kgf-cm, 12 ft-lbf) (j) Connect the switch connector. 2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the cable with the nut. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L bracket of the cable faces the inside of the vehicle. 3. ADJUST SHIFT LEVER POSITION (for Column Shift Type) See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type) 4. ADJUST SHIFT LEVER POSITION (for Floor Shift Type) See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type) Diagrams Alternator: Diagrams Up to 11/2009 Wheel Speed Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 4756 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 Temperature Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Components Transmission Speed Sensor: Service and Repair Components A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS Page 6477 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 8335 Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 8312 Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 5280 Angle of intermediate shaft (C) - Angle of propeller shaft (D) Measured Value (Reference): HINT * Using the following chart, check if the calculated No. 2 joint angle is within the specified value. * The tolerance is +/-0°60' (1.00°). Standard No. 2 joint angle: Page 2911 Camshaft Position Sensor: Diagrams Page 1561 Tire Pressure Warning Reset Switch: Testing and Inspection TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION 1. CHECK TIRE PRESSURE WARNING RESET SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 9148 Body Control Module: Diagrams Page 2865 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection Page 6783 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Diagrams Navigation Display: Diagrams Page 4454 Accelerator Pedal Position Sensor: Diagrams Page 9241 (b) Disconnect the connector. 6. REMOVE REAR DOOR ARMREST COVER LH 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Remove the 2 screws. (b) Using a clip remover, remove the clip. (c) for Standard: (1) Detach the 10 clips and remove the trim board. (d) for 12 Speakers: (1) Detach the 10 clips and remove the trim board. Then disconnect the connector. (e) Disconnect the 2 cables from the inside handle. (f) Remove the inside handle. Reassembly ENGINE HOOD / DOOR: REAR DOOR (for CrewMax): REASSEMBLY Page 3517 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR SHORT TO GND IN CAN BUS WIRE (DLC3 BRANCH WIRE) (a) Disconnect the J86 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step. 3. CONNECT CONNECTOR Page 139 Control Module HVAC: Diagrams A/C Amplifier Page 4390 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay 1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION 1. REMOVE FUEL PUMP RELAY (F/PMP) (a) Remove the fuel pump relay from the engine room relay block. 2. INSPECT FUEL PUMP RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the fuel pump relay. 3. INSTALL FUEL PUMP RELAY (a) Install the fuel pump relay to the engine room relay block. Page 5707 (8) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (9) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (10)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (11)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (12)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (c) Bleed VSC actuator assembly NOTICE: After bleeding the air from the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding of the brake actuator with the Techstream by following the procedure below. (1) Depress the brake pedal more than 20 times with the engine off. (2) Connect the Techstream to the DLC3, and turn the ignition switch on. NOTICE: Do not start the engine. (3) Select AIR BLEEDING on the Techstream. HINT Refer to the Techstream operator's manual for further details. (4) Bleed the air out of the suction line. NOTICE: * Perform the bleeding at the right front wheel and right rear wheel. * Bleed the air by following the steps displayed on the Techstream. (5) 1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel. 2. Loosen the bleeder plug. 3. Operate the brake actuator to bleed the air using the Techstream. HINT This operation stops automatically after 4 seconds. NOTICE: Release the brake pedal at this time. (6) 4. Check if the operation has stopped by referring to the Techstream display. 5. Temporarily tighten the bleeder plug. 6. Repeat the 4 previous steps until all in the fluid is completely bled out. 7. Tighten the bleeder plug. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (7) 8. Repeat all of the above procedures for the other wheel to bleed the air out of the suction line. (8) Bleed the air out of the pressure reduction line. NOTICE: * Perform the bleeding at the 4 wheels. * Bleed the air by following the steps displayed on the Techstream. (9) 1. Connect a vinyl tube to one of the bleeder plugs. Center Airbag Sensor Assembly (for Column Shift Type) Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 2217 Tire Pressure Warning Reset Switch: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING RESET SWITCH (a) Disconnect the switch connector. (b) Detach the 2 claws and remove the reset switch. Page 4937 Locations Integrated Accessory Switch Assembly: Locations METER: METER / GAUGE SYSTEM: PARTS LOCATION Up to 11/2009 Steering Angle Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 462 Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 902 Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 3226 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 8579 HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 14. REMOVE NO. 2 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the rear bumper. Installation PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): INSTALLATION 1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the rear bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 2. INSTALL NO. 1 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. Removal and Replacement Differential Carrier: Removal and Replacement Components DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): COMPONENTS Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Page 7865 (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 14. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Remove the 3 screws and plate. (b) Detach the 3 claws and remove the heater clamp. (c) Remove the heater radiator unit. 16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY Page 4081 NOTICE: Be careful not to damage the installation surface of the gaskets. Page 8352 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Page 2017 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Locations Seat Position Sensor: Locations SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 3150 (4) Remove the 2 bolts and disconnect the water by-pass pipe. (5) Remove the 4 bolts and 4 ignition coils. 4. REMOVE SPARK PLUG (a) Using a 16 mm plug wrench, remove the 8 spark plugs. Page 7565 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL AMBIENT TEMPERATURE SENSOR (a) Attach the clamp to install the ambient temperature sensor. (b) Connect the connector. Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 5098 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 7982 pretensioner activation. 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY HINT * Refer to the procedures up to "REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY" (for Column Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal * Refer to the procedures up to "REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY" (for Floor Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly 4. REMOVE NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly 5. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly 6. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (a) Disconnect the 2 connectors and remove the instrument panel wire from the front passenger airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 2 screws. (c) Detach the 5 hooks (A). (d) Detach the 5 hooks (B) and remove the front passenger airbag from the instrument panel. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY: INSTALLATION Page 7791 Refrigerant Oil: Fluid Type Specifications COMPRESSOR OIL Type...................................................................................................................................................... ..............................................ND-OIL 8 or equivalent Page 705 Power Seat Switch: Diagrams Front Power Seat Switch Page 6684 Engine Room R/B, J/B - Engine Compartment Left Page 3492 NEXT -- Continue to next step. 7. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - COMBINATION METER ECU) (a) Disconnect the J84 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU) OK -- Continue to next step. 8. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - MAIN BODY ECU) (a) Disconnect the J96 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU) OK -- Continue to next step. 9. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A46 No. 1 junction connector connector. Page 671 Removal DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): REMOVAL 1. REMOVE FRONT ARMREST UPPER BASE PANEL LH (a) Using a moulding remover, detach the 2 clips and 5 claws, and remove the armrest base panel. Page 941 4. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) (a) Install the damper servo with the 3 screws, as shown in the illustration. (b) Connect the connector. 5. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. 6. INSTALL BLOWER CASE SUB-ASSEMBLY (a) Attach the 3 claws to install the case. (b) Install the 3 screws. Page 9122 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 8845 (a) Attach the 4 clips and claw to install the speaker panel. 4. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Attach the 4 clips and claw to install the speaker panel. 5. INSTALL FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 6. INSTALL FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): COMPONENTS Page 3246 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 8184 Seat Occupant Classification Module - Air Bag: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 1625 Power Window Switch: Locations Power Window Control System (w/o Jam Protection Function) WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/o Jam Protection Function): PARTS LOCATION Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT TIMING GEAR LH Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) RH Using a wrench to hold the hexagonal portion of the No. 1 camshaft, tighten the camshaft timing gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear with the bolt. Torque.................................................................................................................................................. .................................100 Nm (1020 kgf-cm, 74 ft-lbf) ACC Cut Relay Power Distribution Relay: Testing and Inspection ACC Cut Relay 1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION 1. REMOVE ACC CUT RELAY (a) Remove the clip. (b) Detach the 2 clips and remove the cowl side trim board RH. (c) Remove the relay. 2. INSPECT ACC CUT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL ACC CUT RELAY (a) Install the relay. (b) Attach the 2 clips to install the cowl side trim board RH. (c) Install the clip. Page 3417 (a) Disconnect the J37 integration control and panel assembly connector. (b) Disconnect the J19 air conditioning amplifier assembly connector. (c) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 2. CHECK HARNESS AND CONNECTOR (INTEGRATION CONTROL AND PANEL - BATTERY AND BODY GROUND) (a) Disconnect the J37 integration control and panel assembly connector. (b) Measure the resistance and voltage according to the value(s) in the table below. Standard Resistance: Standard Voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 3. CHECK INTEGRATION CONTROL AND PANEL ASSEMBLY (OPERATION) (a) Temporarily replace the integration control and panel assembly with a new or normally functioning one. Page 1943 (a) Hook the engine under cover to the vehicle body as shown in the illustration. (b) Install the 3 screws and 5 bolts. for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf) Page 3296 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 Oxygen Sensor Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Four Wheel Drive Selector Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 4092 EGR Valve: Service and Repair Installation 1UR-FE EMISSION CONTROL: EGR VALVE: INSTALLATION 1. INSTALL EGR VALVE BRACKET (a) Install the EGR valve bracket with the 3 bolts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 2. INSTALL NO. 3 EGR PIPE SUB-ASSEMBLY (a) Install a new gasket and the No. 3 EGR pipe with the 2 nuts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL EGR INLET (a) Install a new gasket and the EGR inlet with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) NOTICE: Make sure the gasket's claws are not caught between the EGR inlet and EGR valve. 4. INSTALL EGR VALVE ASSEMBLY (a) Install a new gasket to the intake manifold. (b) Install a new gasket to the No. 2 EGR pipe. Page 3947 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 363 ^ 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 2206 Tire Pressure Sensor: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so that the print surface can be seen. NOTICE: * Check that there is no visible deformation, damage or other abnormalities on the tire pressure warning valve and transmitter. * Check that there is no foreign matter on the inner grommet and around the rim hole. * If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be damaged or fail to transmit signals when running at a high speed. * If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before installation. * The transmitter ID registration must be performed for all tire pressure warning valve and transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do not need to be replaced before performing the transmitter ID registration See: Testing and Inspection/Programming and Relearning/Registration * It is necessary to perform initialization See: Testing and Inspection/Programming and Relearning/Initialization after registration See: Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been replaced. (b) If reusing the tire pressure warning valve and transmitter: Install a new grommet. HINT A new tire pressure warning valve and transmitter is supplied with a grommet. (c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut. Page 1651 2. INSTALL FRONT UPPER ARMREST BASE PANEL LH (a) Connect the master switch connector. (b) Attach the 2 clips and 5 claws to install the front upper armrest base panel. Page 6555 J/B No.5 - Instrument Panel Center Page 7633 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. Page 3340 (b) Install the connector holder block cover. 4. INSTALL AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and Repair/Installation 5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 6382 Instrumental Panel Wire Page 2807 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 201 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Transmission Control Switch Transmission Mode Switch: Diagrams Transmission Control Switch Page 503 Steering Control Module: Diagrams Page 5960 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 5746 Removal BRAKE: BRAKE MASTER CYLINDER: REMOVAL NOTICE: Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder sub-assembly from the brake booster assembly. 1. DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. 2. DISCONNECT BRAKE FLUID LEVEL WARNING SWITCH CONNECTOR (a) Disconnect the brake fluid level warning switch connector. 3. DISCONNECT FRONT NO. 1 BRAKE TUBE (a) Using a union nut wrench, disconnect the brake tube (labeled A) from the brake master cylinder. 4. DISCONNECT REAR NO. 1 BRAKE TUBE Page 8271 6. REMOVE REAR SEAT REAR CUSHION MOULDING RH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 7. REMOVE REAR SEAT INNER BELT ASSEMBLY (a) Remove the belt. 8. REMOVE REAR NO. 1 SEAT INNER BELT ASSEMBLY LH (a) Remove the bolt and seat belt. HINT The rear center seat outer belt's anchor is fixed with the same bolt as the rear No. 1 seat inner belt. Therefore, it becomes disconnected when the bolt is removed. Installation SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for CrewMax): INSTALLATION 1. INSTALL REAR NO. 1 SEAT INNER BELT ASSEMBLY LH (a) Install the belt with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) HINT The rear center seat outer belt's anchor is fixed with the same bolt as the rear No. 1 seat inner belt. Therefore, connect it when installing the rear No. 1 seat inner belt. 2. INSTALL REAR SEAT INNER BELT ASSEMBLY Page 2442 Oil Pressure Sender: Service and Repair Installation 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Apply adhesive to 2 or 3 threads of the oil pressure sender gauge. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (b) Install the oil pressure sender gauge. Torque : 15 Nm (153 kgf-cm, 11 ft-lbf) NOTICE: Do not start the engine within 1 hour after installation. (c) Connect the sender gauge connector. 2. INSPECT ENGINE OIL LEVEL See: Testing and Inspection 3. INSPECT FOR OIL LEAK See: Engine Oil/Service and Repair/Replacement 4. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement Page 5894 Traction Control Switch: Diagrams Page 1409 Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BATTERY (a) Disconnect the cable from the positive (+) battery terminal. Components Central Control Module: Service and Repair Components AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: COMPONENTS Page 8266 (a) Remove the bolt and disconnect the outer belt. 2. REMOVE REAR SEAT ASSEMBLY (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 3. REMOVE REAR SEAT BELT RETRACTOR COVER (a) Detach the 2 claws and 2 clips, and remove the cover. 4. REMOVE CENTER REAR SEAT OUTER BELT ASSEMBLY (a) Remove the 4 bolts and outer belt. 5. REMOVE SEAT BELT BRACKET Page 3333 (q) WAVEFORM 16: HINT The wavelength changes when the air injection control driver detects malfunctions in the air injection system See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0412 (r) WAVEFORM 17: HINT The wavelength becomes shorter as engine rpm increases. (s) WAVEFORM 18: Page 638 11. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 4129 Page 8933 Integrated Accessory Switch Assembly: Service and Repair Installation METER: DRIVE MONITOR SWITCH: INSTALLATION 1. INSTALL DRIVE MONITOR SWITCH (a) Attach the 2 claws to install the monitor switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 2762 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 4565 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 6764 PJ1-QK1 Page 6147 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 68 (a) Attach the 8 claws and 2 clips to install the scuff plate. 5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 6736 Engine Room R/B, J/B - Engine Compartment Left Page 552 Control Module: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE 4WD CONTROL ECU (a) Disconnect the 2 ECU connectors. (b) Remove the bolt and ECU. Page 630 Shock Sensor: Diagrams Page 3550 (c) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal Steering Angle Sensor Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Steering Angle Sensor Communication Stop Mode - Steering Angle Sensor Communication Stop Mode DESCRIPTION WIRING DIAGRAM Page 6786 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Components Spark Plug: Service and Repair Components 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS Page 9024 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 2582 (f) Install SST (pressure gauge) as shown in the illustration. SST : 09268-31012 90467-13001 95336-08070 09268-41500 09268-41120 SST : 09268-45014 09268-41200 09268-41220 (g) Wipe off any gasoline. (h) Reconnect the cable to the negative (-) battery terminal. (i) Operate the fuel pump. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. NOTICE: Do not start the engine. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (j) Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (k) If the pressure is higher than the specification, replace the fuel pressure regulator. If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator assembly. (l) Start the engine. Page 8625 Remove the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 8. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 9. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 10. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 11. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 12. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 13. REMOVE STEREO JACK ADAPTER ASSEMBLY (a) Detach the 2 claws and remove the stereo jack adapter. Installation AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL STEREO JACK ADAPTER ASSEMBLY Page 5402 Fluid - Transfer Case: Fluid Type Specifications Transfer Oil Type ..................................................................................................................................................... ....................................... Gear oil API GL-4 or GL-5 Recommended viscosity ................................... ................................................................................................................................................ SAE 75W-90 Engine Controls - ECM Update For Shift Performance Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 2961 Oxygen Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 2614 Spark Plug: Service and Repair Removal 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the MAF meter connector and clamp. (b) Disconnect the ventilation hose and vacuum hose. (c) Loosen the hose clamp. (d) Remove the 2 bolts and air cleaner. 3. REMOVE IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Disconnect the 3 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Remove the 4 bolts and 4 ignition coils. (b) for Bank 2: (1) Disconnect the 2 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Disconnect the engine wire harness clamp. Locations Temperature Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 4180 Page 3237 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 2409 (c) Install the oil cooler with the 5 nuts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 3. INSTALL OIL FILTER BRACKET (a) Apply a light coat of engine oil to 2 new O-rings. (b) Install the 2 O-rings to the timing chain cover. (c) Install the oil filter bracket with the 2 nuts and 2 bolts. Torque : 35 Nm (357 kgf-cm, 26 ft-lbf) 4. INSTALL NO. 1 OIL COOLER BRACKET (a) Connect the ground wire to the cylinder block. (b) Install the oil cooler bracket with the 2 nuts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 5. INSTALL WATER BY-PASS PIPE See: Water Pump/Service and Repair/Installation 6. CONNECT COOLER COMPRESSOR ASSEMBLY See: Oil Pump/Service and Repair/Removal and Replacement/Installation 7. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY See: Oil Pressure Sender/Service and Repair/Installation 8. INSTALL OIL FILTER ELEMENT See: Engine Oil/Service and Repair/Replacement Page 8659 Page 9206 6. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Front Door Speaker (for Double Cab)/Removal 7. REMOVE COURTESY LIGHT ASSEMBLY (a) Detach the claw and remove the courtesy light from the door trim board. (b) Disconnect the connector. 8. REMOVE FRONT DOOR ARMREST COVER LH 9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Remove the 2 screws. (b) Remove the clip. (c) Detach the 9 clips and remove the trim board cover. Then disconnect the connector. (d) Disconnect the 2 cables from the inside handle. Page 8401 Seat Occupant Sensor: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 6119 (b) Hang the plunger of the magnet starter switch onto the drive lever from the upper side. (c) Install the magnet starter switch with the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (d) Connect the lead wire to the magnet starter switch and connect it with the nut. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Disassembly 1UR-FE STARTING: STARTER (for 2.0 kW Type): DISASSEMBLY 1. REMOVE MAGNET STARTER SWITCH ASSEMBLY (a) Remove the nut, and disconnect the lead wire from the magnet starter switch. (b) Remove the 2 nuts and magnet starter switch. 2. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Using a T30 "TORX" socket wrench, remove the 2 bolts. (b) Pull out the yoke and starter commutator end frame assembly together with the armature. Components Interior Light Switch: Service and Repair Components LIGHTING: ROOM LIGHT SWITCH: COMPONENTS Components Transmission Speed Sensor: Service and Repair Components A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS Page 1680 *: for 5 leaf spring Standard Wheel Angle for Regular Cab of Standard Deck Page 2465 (j) Connect the purge VSV connector. (k) Connect the purge line hose to the purge VSV. (l) Connect the vacuum switching valve connector (for ACIS). (m)Connect the No. 1 ventilation hose. (n) Connect the No. 4 water by-pass hose. (o) Connect the throttle body connector. 11. INSTALL VENTILATION HOSE ASSEMBLY (a) Install the ventilation hose with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH. 12. INSTALL AIR TUBE SUB-ASSEMBLY LH See: Cooling System/Thermostat/Service and Repair/Installation 13. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY (a) Install the outer panel with the 7 bolts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the washer hose. (c) Connect the 2 wire harness clamps. 14. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY Page 7499 No further tightening is required once the nut is tightened with the specified torque. 2. INSTALL WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 3. INSPECT TIRE (a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics. 4. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Testing and Inspection/Programming and Relearning/Registration. 5. PERFORM INITIALIZATION (a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 6. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 8669 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3847 5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor connector. (b) Disconnect the air fuel ratio sensor connector. (c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support. (d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH. 7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) for 2WD: Disconnect the air fuel ratio sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION 1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 Page 5763 (d) Remove the bolt and No. 2 parking brake cable from the rear axle carrier. 36. REMOVE PARKING BRAKE INTERMEDIATE LEVER SUB-ASSEMBLY (a) Remove the 2 bolts and intermediate lever with bracket. (b) Remove the clip, washer, pin and intermediate lever from the bracket. 37. REMOVE NO. 2 CABLE SUPPORT BRACKET (a) Remove the 2 bolts and bracket. Page 2628 (a) Remove the 3 bolts and water inlet housing. (b) Remove the gasket from the water pump. 10. REMOVE WATER PUMP PULLEY (a) Using SST, hold the water pump pulley. SST : 09960-10010 09962-01000 09963-01000 (b) Remove the 4 bolts and water pump pulley. 11. REMOVE WATER PUMP ASSEMBLY (a) Remove the 8 bolts, water pump and gasket. Page 1391 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BATTERY (a) Disconnect the cable from the positive (+) battery terminal. (b) Loosen the nut, move the stay off the battery, and remove the battery. 3. REMOVE FRONT AIRBAG SENSOR (a) Remove the nut and front airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Connect the connector. (d) Install the front airbag sensor with the nut. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) Page 1690 for Double Cab of Long Deck Page 3773 Air Flow Meter/Sensor: Diagrams Components Radiator: Service and Repair Components 1UR-FE COOLING: RADIATOR: COMPONENTS Page 1811 ^ 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 6398 Page 7835 Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: REMOVAL 1. REMOVE AMBIENT TEMPERATURE SENSOR (a) Disconnect the connector. (b) Using a screwdriver, detach the clamp and remove the ambient temperature sensor. HINT Tape the screwdriver tip before use. Page 4142 Page 7862 (a) Remove the filter. 6. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (a) Remove the screw and duct. 7. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Remove the 2 screws and amplifier. 8. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY (a) Remove the 3 screws and motor. 9. REMOVE AIR DUCT (a) Remove the 2 screws and duct. Locations Power Distribution Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Name Plate Body Emblem: Service and Repair Name Plate EXTERIOR: NAME PLATE: COMPONENTS Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 6209 (a) for AC Power Supply: Connect the clamp. (b) Install the bezel with the 4 screws. 5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly Components OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): COMPONENTS Removal and Replacement Parking Brake Pedal: Removal and Replacement Components PARKING BRAKE: PARKING BRAKE PEDAL: COMPONENTS Removal PARKING BRAKE: PARKING BRAKE PEDAL: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. RELEASE PARKING BRAKE PEDAL 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 6. DISCONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Remove the lock nut and adjustment nut. Page 6835 Page 1694 for Double Cab of Long Deck Locations Relay Box: Locations Engine Compartment Page 713 Reclining switch (b) If the result is not as specified, replace the switch. 3. INSPECT LEG SUPPORT ADJUSTMENT SWITCH (w/ Leg Support Adjustment Switch) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 811 Steering Angle Sensor: Service and Repair Installation BRAKE CONTROL: STEERING ANGLE SENSOR: INSTALLATION 1. INSTALL STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 2. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 3. INSTALL UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 4. INSTALL LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 5. ADJUST SPIRAL CABLE See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 7. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 8. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 9. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Diagrams Variable Valve Timing Actuator Position Sensor: Diagrams Page 4189 Front Speed Sensor Wheel Speed Sensor: Service and Repair Front Speed Sensor Components BRAKE CONTROL: FRONT SPEED SENSOR: COMPONENTS Removal BRAKE CONTROL: FRONT SPEED SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT SKID CONTROL SENSOR WIRE LH (a) Disconnect the connector (labeled A) from the front speed sensor. (b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C). (c) Disconnect the connector (labeled D). Page 5974 Ignition Switch: Connector Views Air Fuel Ratio Sensor Oxygen Sensor: Diagrams Air Fuel Ratio Sensor Page 3671 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 7162 Tire Pressure Warning Reset Switch: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING RESET SWITCH (a) Disconnect the switch connector. (b) Detach the 2 claws and remove the reset switch. Up to 11/2009 Electronic Brake Control Module: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 3461 Result E -- REPAIR OR REPLACE HARNESS OR CONNECTOR D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal A -- REPLACE ECM Power Steering ECU Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Power Steering ECU Communication Stop Mode - Power Steering ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Skid Control Sensor Wire Wheel Speed Sensor: Diagrams Skid Control Sensor Wire Page 7861 Evaporator Temperature Sensor / Switch: Service and Repair Disassembly AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: DISASSEMBLY 1. REMOVE AIR CONDITIONING UNIT (a) Remove the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Removal. 2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY (a) Detach the 4 claws and remove the nozzle. 3. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (a) Detach the 4 claws and remove the duct. 4. REMOVE AIR FILTER COVER PLATE (a) Detach the 2 clips and remove the plate. 5. REMOVE CLEAN AIR FILTER Page 5728 * The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface. 3. REMOVE REAR BRAKE FLEXIBLE HOSE (a) Disconnect the brake tube from the flexible hose with a union nut wrench while holding the flexible hose with a wrench. NOTICE: * Do not bend or damage the brake tube. * Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting point. (b) Remove the clip. (c) Remove the union bolt and gasket, and then remove the flexible hose from the disc brake cylinder. Installation BRAKE: REAR BRAKE FLEXIBLE HOSE: INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL REAR BRAKE FLEXIBLE HOSE (a) Install the flexible hose and a new gasket to the disc brake cylinder with the union bolt. Torque : 30 Nm (306 kgf-cm, 22 ft-lbf) HINT Install the flexible hose lock securely in the lock hole in the cylinder. (b) Set the flexible hose to the connecting point with the brake tube, and then attach a new clip. (c) Using a union nut wrench, connect the flexible hose to the brake tube while holding the flexible hose with a wrench. Page 8729 Additional SSTs may be ordered by calling 1-800-933-8335. Repair Procedure 1. Verify the condition in the Introduction. 2. Perform diagnostic troubleshooting to confirm the problem is related to the condition described in this TSB. Refer to the Technical Information System (TIS), Accessory - Accessory Diagnostic Guide "2004-2011 All Vehicles XM Satellite Radio Tuner 86180-0W030 Troubleshooting Guide" 3. Order a replacement XM Satellite Radio Receiver through the Pioneer exchange program. For information regarding the satellite radio warranty, refer to TIS, Reference Information Warranty Policy & Procedures -"Policy 4.28: Satellite Radio Warranty" Heated Oxygen Sensor Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE INSPECTION 1. CHECK HEATED OXYGEN SENSOR (a) Disconnect the heated oxygen sensor connector. (b) Measure the heater resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the heated oxygen sensor. (d) Connect the heated oxygen sensor connector. Page 4279 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 5778 Installation PARKING BRAKE: PARKING BRAKE PEDAL: INSTALLATION 1. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY (a) Install the control pedal to the body with the 3 nuts. Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) (b) Attach the wire harness clamp to the control pedal. Page 7195 (b) Using SST and a press, press in the oil seal. SST : 09950-60010 09951-00280 SST : 09950-70010 09951-07100 NOTICE: Make sure that the oil seal is installed facing in the correct direction as shown in the illustration. 2. INSTALL VANE PUMP SHAFT SUB-ASSEMBLY WITH PULLEY (a) Coat the inside surface of the bushing in the vane pump front housing with power steering fluid. (b) Gradually insert the vane pump shaft sub-assembly with pulley. NOTICE: * Do not damage the lip of the oil seal in the front housing. * Wrap protective tape around the spline of the vane pump shaft with vane pump shaft sub-assembly with pulley in order to prevent damage to the oil seal. 3. INSTALL VANE PUMP FRONT SIDE PLATE (a) Coat a new O-ring with power steering fluid and install it into the front housing. (b) Coat a new O-ring with power steering fluid and install it onto the front side plate. Fuel System - Fuel Sending Unit Upper Cover Replacement Fuel Gauge Sender: Technical Service Bulletins Fuel System - Fuel Sending Unit Upper Cover Replacement T-SB-0399-09 December 23, 2009 Fuel Sending Unit Upper Cover Installation Service Category Engine/Hybrid System Section Fuel System Market USA Applicability Introduction A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010 MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair Manual by providing the installation procedures and part number details for this component. Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit Upper Cover. Production Change Information This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 6649 (a) Attach the claw to install the power outlet socket. 3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) Components OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS Page 8265 Removal SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): REMOVAL 1. DISCONNECT CENTER REAR SEAT OUTER BELT ASSEMBLY Page 9004 Page 2800 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 9313 (3) Attach the 2 clips to install the moulding. HINT Press the moulding firmly to install it. Diagrams Tilt Wheel Motor: Diagrams Page 8639 (a) Attach the clip and 2 claws to install the bracket. (b) Install the 4 bolts. HINT Install the bolts in the order shown in the illustration. 2. INSTALL ROOF HEADLINING ASSEMBLY (for CrewMax) (a) Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 3. INSTALL TELEVISION DISPLAY ASSEMBLY (a) Attach the 2 clips and 2 claws to install the television display. (b) Install the 4 bolts. HINT Install the bolts in the order shown in the illustration. 4. INSTALL ROOM NO. 1 LIGHT ASSEMBLY Page 269 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 4973 Transmission Speed Sensor: Diagrams Page 924 Compressor Speed Sensor: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 6773 Multiple Junction Connector: Locations Wire and Wire In Seat [Separate Seat] PZ1-ZU1 PZ1-ZU1 Page 7872 (a) Install the motor with the 3 screws. 11. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the amplifier with the 2 screws. 12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (a) install the duct with the screw. 13. INSTALL CLEAN AIR FILTER (a) Install the filter as shown in the illustration. 14. INSTALL AIR FILTER COVER PLATE (a) Attach the 2 clips to install the plate. Components Parking Assist Control Module: Service and Repair Components PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: COMPONENTS Page 5297 09957-04010 09958-04011 SST : 09955-04100 NOTICE: Pull out the spider bearing until the SST claws contact the flange yoke. (k) Clamp the protruding universal joint spider bearing in a vise. (l) Using a brass bar and hammer, tap the flange yoke to remove the universal joint spider bearing. HINT Use the same removal procedure for the universal joint spider bearing on the opposite side. (m)Remove the spider from the flange yoke. Reassembly PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): REASSEMBLY 1. INSTALL REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING HINT Use the same installation procedure for both the front and rear propeller shaft universal joint spider bearings. (a) Apply MP grease to a new spider and 4 new bearings. NOTICE: Be careful not to apply too much grease. (b) Measure dimension A between the snap ring grooves. (c) Install the 4 spider bearings to the spider journal portions, and then measure dimension B of the universal joint. Page 4029 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Check Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 8941 Parking Assist Distance Sensor: Diagrams Page 3639 Power Steering Pressure Switch: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install a new O-ring to the power steering oil pressure switch. (b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch. NOTICE: * When reusing the power steering oil pressure switch, inspect the O-ring. * If the O-ring has scratches or cuts, replace the power steering oil pressure switch. (c) Using SST, install the power steering oil pressure switch. SST : 09922-10010 without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the torque wrench are connected in a straight line. (d) Connect the oil pressure switch connector. 2. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 3. ADD POWER STEERING FLUID 4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 5. INSPECT FOR POWER STEERING FLUID LEAK 6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Page 1328 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Diagrams Keyless Entry Receiver: Diagrams Page 6035 Page 6482 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 4394 8110 - 10-Pc. Line Disconnect Set Page 4948 (c) Replace the ATF in the torque converter clutch. (1) If the ATF is discolored and/or has a foul odor, stir the ATF in the torque converter clutch thoroughly and drain the ATF with the torque converter facing upward. (d) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When any marks due to interference are found on the end of a bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and torque converter clutch. (2) Make sure all of the bolts are the same length. (3) Make sure no spring washers are missing. 2. INSPECT DRIVE PLATE (a) Check the drive plate for damage. (b) Set up a dial indicator and measure the runout of the 6 portions around the torque converter clutch contact surfaces. Maximum runout: 0.30 mm (0.0118 in.) (c) If the runout is more than the maximum, or the drive plate is damaged, replace the drive plate See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation. Page 1763 Spark Plug: Service and Repair Installation 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION 1. INSTALL SPARK PLUG (a) Using a 16 mm plug wrench, install the 8 spark plugs. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 2. INSTALL IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors. (3) Connect the 3 wire harness clamps. (b) for Bank 2: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors and 2 wire harness clamps. (3) Connect the water by-pass pipe with the 2 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) Page 4125 Page 2499 Oil Pressure Sender: Testing and Inspection 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Disconnect the sender gauge connector. (b) Apply battery positive (+) voltage to the sender gauge terminal through a test LED. (c) Check that the LED does not illuminate when the engine is stopped. (d) Check that the LED flashes when the engine is running. The number of flashes varies with engine speed. If the operation is not as specified, replace the oil pressure sender gauge assembly. Recall 10V091000: Front Driveshaft Replacement Drive/Propeller Shaft: All Technical Service Bulletins Recall 10V091000: Front Driveshaft Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Tundra 2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: March 09, 2010 NHTSA CAMPAIGN ID NUMBER: 10V091000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Axle Assembly: Axle Shaft POTENTIAL NUMBER OF UNITS AFFECTED: 2 SUMMARY: Toyota is recalling certain model year 2010 Tundra vehicles with four wheel drive, there is a possibility that an improper weld exists at the union of the propeller shaft and yoke. Due to this improper weld, this joint may separate and the separated shaft may come into contact with the road surface. CONSEQUENCE: This may result in a loss of vehicle control increasing the risk of a crash. REMEDY: Dealers will replace the front propeller shaft free of charge. The safety recall is expected to begin during March 2010. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 7969 Tire size: Must exceed the following dimensions Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) CAUTION: * Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the front seat side airbag may become loose due to the shock when the airbag is deployed. * Always tie down the front seat side airbag with the airbag deployment direction facing inside the tire. NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (d) Install SST. (1) Connect SST connector to the front seat airbag connector. SST : 09082-00820 (e) Place the tires. (1) Place at least 2 tires under the tire which the front seat side airbag is tied to. (2) Place at least 2 tires over the tire which the front seat side airbag is tied to. The top tire should have the disc wheel installed. NOTICE: * Do not place SST connector under the tire because it could be damaged. * As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. * As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (3) Tie the tires together with 2 wire harnesses. Page 9029 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Locations Trailer Towing Relay: Locations Engine Room R/B, J/B - Engine Compartment Left Page 6682 Engine Room R/B, J/B - Engine Compartment Left Components Tire Pressure Sensor: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS Page 6948 Driver Side J/B Inner Circuit Page 95 Sunroof / Moonroof Module: Diagrams Specifications Compression Check: Specifications COMPRESSION Page 8107 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): COMPONENTS Page 23 (a) Disconnect the connectors. (b) Remove the 2 nuts and junction block. (c) Remove the nut and ECU. Components Actuator: Service and Repair Components DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): COMPONENTS Components Tire Pressure Monitor Receiver / Transponder: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS Page 6544 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 6057 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 7128 Power Steering Pressure Switch: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: REMOVAL 1. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DRAIN POWER STEERING FLUID 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the power steering oil pressure switch connector. (b) Remove the power steering oil pressure switch. (c) Remove the O-ring. Page 3412 HINT * o: DTC is memorized. * *1: Only during failure status. Fail-Safe Chart CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: FAIL-SAFE CHART 1. FAIL-SAFE FUNCTION (a) When communication fails in any of the main wires (communication lines) due to a short circuit or other causes, the fail-safe function, which is specified for each system, operates to prevent the system from malfunctioning. (b) The table below shows the effects on each system when communication is impossible. For further details, refer to each system. Page 8140 Seat Occupant Sensor: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 8172 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Engine Immobiliser System Alarm Module: Locations Engine Immobiliser System ENGINE IMMOBILISER: ENGINE IMMOBILISER SYSTEM: PARTS LOCATION Page 415 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection Page 4621 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Page 2091 J/B No.4 - Instrument Panel Center Page 8668 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Locations Engine Temperature Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 2806 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 8291 Page 6462 Relay Box: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transmission Fluid Capacities: With tow package: 2WD ..................................................................................................................................................... .......................................................... 12.3 qt (11.6L) 4WD ................................................................. .............................................................................................................................................. 11.9 qt (11.3L) Without tow package: 2WD ..................................................................................................................................................... .......................................................... 11.7 qt (11.7L) 4WD ................................................................. .............................................................................................................................................. 11.4 qt (10.8L) Page 3408 HINT * o: DTC is memorized. * *1: Only during failure status. Diagrams Steering Angle Sensor: Diagrams Page 6454 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 3724 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK Page 1164 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 2348 (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation 6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation Locations Collision Avoidance System Switch: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 4265 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 3741 Engine Control Module: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and Repair/Removal 3. DISCONNECT CONNECTOR HOLDER BLOCK (a) Remove the connector holder block cover. (b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in the next step. 4. REMOVE ECM (a) Disconnect the wire harness clamp. (b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration. NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before disconnecting the connectors. Failure to do this may cause the connectors to break. (c) Disconnect the 2 connectors. (d) Remove the 4 bolts and ECM. 5. REMOVE GASKET (a) Peel off the rubber part of the gasket. Page 4737 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 7988 (b) Disconnect the 2 clamps. (c) Remove the 2 nuts and the front seat side airbag assembly. CAUTION: * The nuts must not be reused. * Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold Down Seat Type): INSTALLATION CAUTION: Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. HINT Use the same procedures for the LH side and RH side. 1. INSTALL FRONT SEAT SIDE AIRBAG ASSEMBLY CAUTION: * The nuts must not be reused. * Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one. (a) Install the front seat side airbag assembly with 2 new nuts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) (b) Connect the 2 clamps. (c) Connect the 3 wire harness clamps to under the seat. Page 8098 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 1635 Standard Resistance: (2) If the result is not as specified, replace the power window regulator switch assembly. (b) Check that the LED illuminates. (1) Apply battery voltage to the power window regulator switch and check that the LED illuminates. OK: (2) If the result is not as specified, replace the power window regulator switch assembly. Page 1485 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 6909 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 6964 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. Page 6908 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 8273 (a) Connect the seat belt with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body. 7. INSTALL REAR NO. 1 SEAT INNER BELT ASSEMBLY RH (a) Install the belt with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 8. INSTALL REAR SEAT ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Crewmax RH Side)/Installation Components SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for Double Cab): COMPONENTS Locations Engine Temperature Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 3677 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 6758 Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Column Shift] AJ1-QK1 Page 5840 Acceleration/Deceleration Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8841 Page 428 Fuel Pump Control Unit: Service and Repair Installation 1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION 1. INSTALL FUEL PUMP ECU (a) Install the fuel pump ECU with the 2 bolts. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being dropped, etc. (b) Connect the 2 fuel pump ECU connectors. Page 639 Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Column Shift Type) Components THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): COMPONENTS Removal THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH Page 3484 Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (STEERING ANGLE SENSOR) OK -- REPLACE STEERING ANGLE SENSOR 8. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU) NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR)". (a) Disconnect the J59 bus buffer ECU connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR) A -- Continue to next step. 9. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Page 1965 2. Loosen the bleeder plug. 3. Using the Techstream, operate the brake actuator, completely depress the brake pedal and hold it there. HINT The operation stops automatically after 4 seconds. When performing this procedure continuously, set an interval of at least 20 seconds. NOTICE: * During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid comes out of the bleeder plug. * Depress and hold the brake pedal. Do not depress and release the pedal repeatedly. (10)4. Tighten the bleeder plug, and then release the brake pedal. 5. Repeat the 3 previous steps until all air in the fluid is completely bled out. 6. Tighten the bleeder plug. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (11)7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure reduction line. (12)Clear the DTCs See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. (13)Inspect for brake fluid leak. (14)Check and adjust brake fluid level in reservoir See: Fluids/Brake Fluid/Testing and Inspection. (15)If any DTC is set, perform the troubleshooting for the DTC (16)Check the DTC See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. Page 8092 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS Components Tire Pressure Sensor: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS Page 1199 A/F and 02 Sensor Identification Locations Entertainment System Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 609 Replacement/Rear Bumper (for Resin Type Bumper)/Installation 7. INSTALL REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 8. INSTALL REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 9. INSTALL REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 10. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 11. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 12. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 13. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 5448 Four Wheel Drive Selector Switch: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION 1. INSTALL 4WD CONTROL SWITCH (a) Attach the 3 claws to install the switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Removal and Replacement Control Arm: Removal and Replacement Components SUSPENSION: FRONT UPPER SUSPENSION ARM: COMPONENTS Removal SUSPENSION: FRONT UPPER SUSPENSION ARM: REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. Page 8580 3. INSTALL NO. 2 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the rear bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 4. INSTALL NO. 2 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. 5. INSTALL REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 6. INSTALL REAR BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Page 3070 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 3720 (a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE OK -- Continue to next step. 2. INSPECT RELAY (IG2, EFI) (a) Remove the integration relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 67 2. REMOVE REAR DOOR SCUFF PLATE RH (a) Detach the 8 claws and 2 clips, and remove the scuff plate. 3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 5. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. INSTALL REAR DOOR SCUFF PLATE RH Locations Gear Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 641 (a) Detach the 4 clips. (b) Disconnect the connector and remove the panel. 11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE (a) Detach the 2 claws and remove the sensor. Installation THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE (a) Attach the 2 claws to install the sensor. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY Page 4837 Fluid - A/T: Service and Repair A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT NOTICE: * This transmission requires Toyota Genuine ATF WS. * After servicing the transmission, you must follow the ATF adjustment procedure. * Maintain the vehicle in a horizontal position while adjusting the fluid level. 1. PRELIMINARY PROCEDURES (a) w/ Trailer Towing System (with transmission oil thermostat): (1) Using compressed air, etc., blow dust off the thermostat cap to clean it. (2) Using a screwdriver, push in the shaft of the thermostat. HINT * Distance pushed: 5.5 to 7.0 mm (0.217 to 0.276 in.) * Push the shaft until the screwdriver contacts the step inside the cap. (3) With the shaft of the thermostat pressed, push a pin into a hole in the side of the thermostat cap. Insert the pin until it passes through the hole in the other side of the thermostat cap to fix the shaft in place. HINT Pin diameter: 1.0 to 1.8 mm (0.0394 to 0.0709 in.) 2. BEFORE FILLING TRANSMISSION * When you have replaced the entire transmission, transmission pan, drain plug, valve body and/or torque converter, proceed to the "Transmission Fill" procedures. Components Four Wheel Drive Selector Switch: Service and Repair Components JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS Page 1132 Accelerator Pedal Position Sensor: Diagrams Page 1366 5. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System Page 3946 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 3500 OK -- REPLACE BUS BUFFER ECU 25. CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU) (a) Disconnect the A25 4WD control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU (CANH, CANL) OK -- REPLACE 4WD CONTROL ECU 26. CHECK FOR SHORT IN CAN BUS WIRES (ECM) (a) Disconnect the A24 ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Result E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL) D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal Page 8033 5. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System Page 9021 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 1902 Coolant: Fluid Type Specifications Coolant Type Use either of the following: "Toyota Super Long Life Coolant" Similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. Do not use plain water alone. Page 9210 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Testing and Inspection Interior Light Switch: Testing and Inspection LIGHTING: ROOM LIGHT SWITCH: INSPECTION 1. INSPECT ROOM LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. (c) Inspect the switch illumination. (1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 4 (ILL-). (2) Check that the light comes on. OK: Light illuminates. (3) If the result is not as specified, replace doom light switch. Page 4192 Page 6104 Minimum length: 9.0 mm (0.354 in.) (b) If the length is less than the minimum, replace the starter brush holder assembly. (c) Inspect the load of the brush spring. (1) Take a pull scale reading immediately after the brush spring separates from the brush. Standard spring load: 16 to 20 N (1.7 to 2 kgf, 3.6 to 4.5 lbf) Minimum spring load: 6.7 N (0.7 kgf, 1.5 lbf) (2) If the load is less than the minimum, replace the starter brush holder assembly. 5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Check the gear teeth on the planet gears, and the internal gear and pinion gear of the starter center bearing clutch for wear or damage. If any of the gears is damaged, replace the gear or starter center bearing clutch sub-assembly. (b) Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. (c) If the result is not as specified, replace the starter center bearing clutch sub-assembly. Airbag System Seat Occupant Classification Module - Air Bag: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 8883 Central Control Module: Service and Repair Installation AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: INSTALLATION 1. INSTALL MULTI-DISPLAY CONTROLLER BRACKET A (a) Install the multi-display controller bracket A with the 2 bolts. Torque : 2.0 Nm (20 kgf-cm, 17 in-lbf) 2. INSTALL MULTI-MEDIA INTERFACE ECU (a) Connect the connector. (b) Install the multi-media interface ECU with the nut. Torque : 8.0 Nm (81 kgf-cm, 70 in-lbf) 3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 9219 3. INSTALL COURTESY LIGHT ASSEMBLY (a) Attach the claw to install the courtesy light. (b) Connect the connector. 4. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Front Door Speaker (for Double Cab)/Installation 5. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (a) Attach the 3 clips to install the front door lower frame bracket garnish. 6. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Install the power window regulator master switch with the 3 screws. 7. INSTALL FRONT UPPER ARMREST BASE PANEL LH (a) Connect the connectors. Page 7218 (a) Attach the claw to install the upper steering column cover. (b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish panel. (c) Install the 2 screws. Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf) HINT Turn the steering wheel to the right and left as necessary to install the 2 screws. 8. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 5987 Neutral Safety Switch: Adjustments A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT 1. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Loosen the bolt of the park/neutral position switch and move the shift lever to N. (b) Align the groove with the neutral basic line. (c) Hold the switch in position and tighten the bolt. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (d) After the adjustment, perform the on-vehicle inspection See: Testing and Inspection/Initial Inspection and Diagnostic Overview. Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Components Variable Valve Timing Actuator Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS Page 7987 CAUTION: * Be sure to read Precaution thoroughly before servicing See: Service Precautions * If the side airbag was deployed, replace the front seat assembly with a new one. * Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. HINT Use the same procedures for the LH side and RH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait for 90 seconds after disconnecting the cable to prevent the airbag and seat belt pretensioner from deploying See: Service Precautions 2. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Remove the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 3. REMOVE VERTICAL ADJUSTING HANDLE LH (for 8 Way Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 4. REMOVE VERTICAL SEAT ADJUSTER KNOB LH (for 8 Way Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 5. REMOVE RECLINING ADJUSTER RELEASE HANDLE LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 6. REMOVE FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 7. REMOVE INNER FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 8. REMOVE FRONT SEAT HEADREST ASSEMBLY LH (for Manual Seat) 9. REMOVE FRONT SEATBACK COVER WITH PAD LH (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 10. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Remove the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 11. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 12. REMOVE RECLINING POWER SEAT SWITCH KNOB LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 13. REMOVE FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 14. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH (for Power Seat) See: Seat Belt Systems/Seat Belt/Service and Repair/Removal and Replacement/Front Seat Inner Belt Assembly/Removal 15. REMOVE INNER FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 16. REMOVE FRONT SEATBACK COVER WITH PAD LH (for Power Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 17. REMOVE FRONT SEAT SIDE AIRBAG ASSEMBLY (a) Disconnect the 3 wire harness clamps from under the seat. Page 3444 Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR) OK -- Continue to next step. 10. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR STEERING ANGLE SENSOR) (a) Disconnect the J87 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR) OK -Continue to next step. 11. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - POWER STEERING ECU) NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)". (a) Disconnect the J115 No. 1 junction connector connector. Diagrams Brake Warning Indicator: Diagrams Locations Collision Avoidance Module: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Transmission Control Switch Transmission Mode Switch: Diagrams Transmission Control Switch Removal and Replacement Grille: Removal and Replacement Components EXTERIOR: RADIATOR GRILLE: COMPONENTS Installation EXTERIOR: RADIATOR GRILLE: INSTALLATION HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL LOWER RADIATOR GRILLE BRACKET LH Page 7334 Front Steering Knuckle: Service and Repair Installation AXLE: STEERING KNUCKLE: INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL KNUCKLE GREASE RETAINER CAP LH (for 2WD) (a) Using a brass bar and hammer, tap in a new retainer cap. NOTICE: * The retainer cap is a non-reusable part. * Do not damage the retainer cap. 2. INSTALL STEERING KNUCKLE OIL SEAL LH (a) Using SST and a press, press in a new oil seal. SST : 09950-60020 09951-01030 SST : 09950-70010 09951-07100 NOTICE: * The oil seal is a non-reusable part. * Do not damage the steering knuckle oil seal. 3. INSTALL STEERING KNUCKLE LH (a) Install the front suspension upper arm to the steering knuckle with the nut. Torque : 110 Nm (1,122 kgf-cm, 81 ft-lbf) (b) Install a new clip. HINT If the holes for the clip are not aligned, tighten the nut up to another 60. 4. CONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Control Arm/Service and Repair/Removal and Replacement/Front Lower Suspension Arm/Installation 5. CONNECT TIE ROD END SUB-ASSEMBLY LH See: Steering/Steering Gear/Service and Repair/Removal and Replacement/Installation Page 76 6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 2020 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 4759 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 6202 (a) Attach the claw to install the power outlet socket. 6. INSTALL CONSOLE BOX BEZEL (a) Attach the 5 claws to install the console box bezel. (b) Connect the connector. 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Components OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Page 6221 Auxiliary Power Outlet Switch: Service and Repair Removal OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INVERTER MAIN SWITCH (a) Detach the 2 claws and remove the main switch. Page 4714 Four Wheel Drive Selector Switch: Testing and Inspection JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION 1. INSPECT 4WD CONTROL SWITCH (a) Check the harness and connector (ECU - battery and body ground). (1) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage: (2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning, repair or replace harness or connector. If the harness or connector is normal, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. Standard resistance: (3) If there is a malfunction, repair or replace the harness or connector. (b) Check the harness and connector (switch - ECU). (1) Disconnect the A25 ECU connector. (2) Disconnect the L1 switch connector. (3) Measure the resistance according to the value(s) in the table below. Page 4179 Page 8226 Prepare a battery to activate the seat belt pretensioner. (a) Check if SST is functioning properly. SST : 09082-00700 CAUTION: When activating the seat belt pretensioner, always use the specified SST. (1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. HINT Do not connect the yellow connector. The yellow connector is used to connect to the seat belt pretensioner. (2) Press SST activation switch and check that the LED of SST activation switch illuminates. CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be malfunctioning. Replace SST with a new one. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the cable from the negative (-) battery terminal. (2) Remove the front door opening trim weatherstrip See: Removal and Replacement/Front Seat Outer Belt Assembly (for Regular Cab)/Removal. (3) Remove the front door scuff plate See: Removal and Replacement/Front Seat Outer Belt Assembly (for Regular Cab)/Removal. (4) Remove the lower quarter trim panel See: Removal and Replacement/Front Seat Outer Belt Assembly (for Regular Cab)/Removal. Page 7364 (b) Press down on the vehicle several times to stabilize the suspension. 3. TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING (a) Tighten the nut. Torque : 195 Nm (1988 kgf-cm, 144 ft-lbf) (b) Tighten the 4 upper nuts in diametrically opposite pairs. Torque : 45 Nm (459 kgf-cm, 33 ft-lbf) (c) Check that the first nut that was tightened is at the torque specification. 4. INSTALL FRONT WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) Disposal SUSPENSION: FRONT SHOCK ABSORBER: DISPOSAL 1. DISPOSE OF FRONT SHOCK ABSORBER ASSEMBLY LH (a) Fully extend the shock absorber rod. Page 8953 3. INSTALL NO. 2 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the rear bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 4. INSTALL NO. 2 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. 5. INSTALL REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 6. INSTALL REAR BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Page 8492 (a) Attach the 8 claws and 2 clips to install the scuff plate. 5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 7786 * Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat. * Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass. 3. WARM UP ENGINE (a) Warm up the engine at less than 1500 rpm for 1 minute or more after charging the refrigerant. NOTICE: Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor. 4. CHECK FOR REFRIGERANT GAS LEAK (a) After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector. (b) Perform the operation under the following conditions: * The ignition switch is OFF. * The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. * Some refrigerant is remaining in the refrigerant system. * The compressor is off and its pressure is approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi). (c) Using a halogen leak detector, check the refrigerant line for leakage. (d) If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test. (e) Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test. Page 3331 HINT The wavelength becomes shorter as the vehicle speed increases. (k) WAVEFORM 10: HINT The duty ratio varies depending on the throttle actuator operation. (l) WAVEFORM 11: HINT The duty ratio varies depending on the throttle actuator operation. (m)WAVEFORM 12: Page 7045 (a) Bounce the vehicle up and down at the corners to stabilize the suspension, and then inspect the toe-in. Standard toe-in (unloaded vehicle): for Regular Cab of Standard Deck Standard toe-in (unloaded vehicle): for Regular Cab of Long Deck Standard toe-in (unloaded vehicle): for Double Cab of Standard Deck Page 1418 Page 9376 13. Reinstall the body plugs for the cab mount bolt holes and then the carpet. 14. Test drive vehicle to confirm the condition has improved. Page 6552 Driver Side J/B - Cowl Side Left Page 7660 Compressor HVAC: Connector Views Page 7599 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 2893 Accelerator Pedal Position Sensor: Diagrams Page 3338 (b) Spray gasket remover or equivalent on the remaining tape of the gasket. NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth. (c) Remove the tape of the gasket without using bladed objects. Page 6169 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Locations Oxygen Sensor Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 2958 Page 9138 Connectors Part 2 Page 7629 Page 3561 4. CHECK DLC3 (a) Measure the resistance according to the value(s) in the table below. 5. CHECK SKID CONTROL ECU WITH ACTUATOR (a) Disconnect the A17 ECU connector. (b) Measure the resistance according to the value(s) in the table below. 6. CHECK MAIN BODY ECU Locations Hazard Warning Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 3407 The steering angle sensor is connected to the CAN communication system but CAN communication DTCs are not output. (h) CENTER AIRBAG SENSOR HINT The center airbag sensor is connected to the CAN communication system but CAN communication DTCs are not output. (i) POWER STEERING ECU For vehicles with a power steering ECU only. HINT The power steering ECU is connected to the CAN communication system but CAN communication DTCs are not output. (j) 4WD CONTROL ECU For vehicles with 4WD only. HINT The 4WD control ECU is connected to the CAN communication system but CAN communication DTCs are not output. (k) BUS BUFFER ECU For vehicles with a bus buffer ECU only. HINT The bus buffer ECU is connected to the CAN communication system but CAN communication DTCs are not output. (l) FRONT POWER SEAT CONTROL ECU AND SWITCH LH For vehicles with a front power seat control system (w/ Seat Memory) only. HINT The front power control seat ECU and switch LH is connected to the CAN communication system but CAN communication DTCs are not output. (m)OUTER MIRROR CONTROL ECU For vehicles with a front power seat control system (w/ Seat Memory) only. HINT The outer mirror control ECU and switch LH is connected to the CAN communication system but CAN communication DTCs are not output. 4. DTC COMBINATION TABLE Components Cruise Control Switch: Service and Repair Components CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: COMPONENTS Page 7049 Standard wheel angle (unloaded vehicle): for Double Cab of Standard Deck Page 9298 Page 145 Control Module HVAC: Service and Repair Installation AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: INSTALLATION 1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the amplifier with the 2 screws. (b) for Manual Air Conditioning System: Connect the 2 connectors. (c) for Automatic Air Conditioning System: Connect the 3 connectors. 2. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (a) Install the duct with the screw. 3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY for Column Shift Type: Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. for Floor Shift Type: Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL LOWER INSTRUMENT PANEL for Column Shift Type: Page 5289 Do not tap the shaft tube. HINT Remove the bearing on the opposite side using the same procedure. (c) Install the 2 removed spider bearing outer races to the spider. (d) Using SST, push the bearing out of the flange yoke. SST : 09332-25010 HINT Before installing SST, sufficiently raise the part labeled A. If part A is too low, SST may be difficult to install. (e) Clamp the outer bearing race in a vise and tap off the flange yoke with a hammer. (f) Remove the spider. HINT Remove the bearing on the opposite side using the same procedure. Reassembly PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: REASSEMBLY 1. INSTALL FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Apply MP grease to a new spider and bearings. NOTICE: Be careful not to apply too much grease. (b) Fit the spider to the yoke. Page 4278 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 4585 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 3693 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 2534 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 3837 Oxygen Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Components Steering Column Control Module: Service and Repair Components STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): COMPONENTS Locations Solar Sensor: Locations AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Up to 11/2009 Brake Fluid Pressure Sensor/Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8350 Page 7647 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 1512 Neutral Safety Switch: Adjustments A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT 1. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Loosen the bolt of the park/neutral position switch and move the shift lever to N. (b) Align the groove with the neutral basic line. (c) Hold the switch in position and tighten the bolt. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (d) After the adjustment, perform the on-vehicle inspection See: Testing and Inspection/Initial Inspection and Diagnostic Overview. Page 8521 Shock Sensor: Diagrams Page 913 Cabin Temperature Sensor / Switch: Testing and Inspection AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): INSPECTION 1. INSPECT ROOM TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the thermistor. NOTICE: * Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. * When measuring the resistance, the sensor temperature must be the same as the ambient temperature. Page 978 Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 3787 Camshaft Position Sensor: Diagrams Page 5913 (c) Disconnect the connector (labeled D). (d) Remove the connector (labeled D) from the skid control sensor clamp (labeled H). (e) Remove the 2 bolts (labeled E) and 2 harness clamps (labeled F). (f) Remove the bolt (labeled G) and skid control sensor clamp (labeled H). 7. REMOVE FRONT SPEED SENSOR RH (a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the knuckle. 8. REMOVE FRONT SKID CONTROL SENSOR CLAMP RH (a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle. Installation BRAKE CONTROL: FRONT SPEED SENSOR: INSTALLATION 1. INSTALL FRONT SKID CONTROL SENSOR CLAMP LH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle. Up to 11/2009 Braking Sensor/Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 2818 Procedures Air Bag: Procedures Front Passenger Side Knee Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY: DISPOSAL HINT When scrapping a vehicle equipped with the SRS or disposing of the lower No. 2 instrument panel airbag, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the service dept. of the distributor. CAUTION: * Never dispose of a lower No. 2 instrument panel airbag that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No. 2 instrument panel airbag. * The lower No. 2 instrument panel airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag with a deployed airbag. * Do not apply water, etc. to a lower No. 2 instrument panel airbag with a deployed airbag. * Always wash your hands with water after completing the operation. * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. (d) Remove the lower No. 2 instrument panel airbag See: Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal. (e) Install SST. (1) Connect SST connector to the lower No. 2 instrument panel airbag. SST : 09082-00700 SST : 09082-00780 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Components Engine Oil: Service and Repair Components 1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS Page 3068 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. Page 997 Parts Information NOTE The fuel sending unit lower cover is installed and supplied as part of the fuel tank assembly part numbers listed in the part information table above. Warranty Information Installation Procedure 1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover (2 places). 2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1 place). Page 1503 Page 2583 (m)Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (o) Stop the engine. (p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Standard fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or higher (q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and carefully remove SST and the fuel tube connector to prevent gasoline from spraying. (s) Reconnect the fuel tube (fuel tube connector). (t) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. Page 6748 Driver Side J/B Inner Circuit Diagrams Power Steering Pump: Diagrams Page 1711 Standard camber inclination (unloaded vehicle): for CrewMax of standard deck Page 6517 Page 3557 (a) Disconnect the N12 front power window regulator motor assembly LH connector. (b) Measure the voltage and resistance according to the value(s) in the table below. * If the result is not as specified, there may be a malfunction on the wire harness side. 4. CHECK FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY RH (for Power Window Control System [w/ Jam Protection Function]) (a) Disconnect the M11 front power window regulator motor assembly RH connector. (b) Measure the voltage and resistance according to the value(s) in the table below. * If the result is not as specified, there may be a malfunction on the wire harness side. 5. CHECK SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF ECU) (w/ Sliding Roof System) (a) Disconnect the W3 sliding roof drive gear sub-assembly connector. (b) Measure the voltage and resistance according to the value(s) in the table below. (c) If the result is not as specified, there may be a malfunction on the wire harness side. 6. CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY (A/C ECU) Page 9081 Trailer Towing Part 3 Page 4141 Page 7425 Tire Pressure Module: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 1334 Ignition Switch: Connector Views Page 8044 Clockspring Assembly / Spiral Cable: Testing and Inspection SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: INSPECTION 1. REMOVE SPIRAL CABLE (a) If there are any defects as mentioned below, replace the spiral cable with a new one: Scratches, cracks, dents or chips on the connector or the spiral cable. (b) Check the spiral cable. (1) Set the spiral cable to the center position See: Service and Repair/Installation. (2) After setting the spiral cable to the center position, rotate the spiral cable 2.5 times clockwise, and measure the resistance as shown. Then rotate the spiral cable 5 times counterclockwise, measure the resistance according to the U4 (uecs) in the table below. Standard resistance: Page 9216 (a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel. HINT Tape the screwdriver tip before use. 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (a) Using a screwdriver, detach the 2 clips and front armrest upper base panel. HINT Tape the screwdriver tip before use. (b) Disconnect the connectors. 4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Remove the 3 screws and power window regulator master switch. 5. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (a) Detach the 3 clips and remove the door lower frame bracket garnish. Diagrams Fuel Tank Pressure Release Valve: Diagrams Page 3938 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 6805 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 9103 Page 6804 Components Steering Control Module: Service and Repair Components POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS 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 7109 9. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 8942 Page 2768 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 3618 Removal 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL CAUTION: * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 3. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Disconnect the heated oxygen sensor connector and 2 clamps. (b) Disconnect the air fuel ratio sensor connector. (c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH. 4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Using SST, remove the sensor. SST : 09224-00010 Page 8237 4. INSTALL CENTER FRONT SEAT ASSEMBLY (a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation. 5. INSTALL FRONT SEAT ASSEMBLY RH (a) for Power Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. (b) for Manual Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. 6. INSTALL FRONT SEAT ASSEMBLY LH (a) for Power Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. (b) for Manual Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. Components SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): COMPONENTS Page 1773 Drive Belt: Service and Repair Removal 1UR-FE ENGINE MECHANICAL: DRIVE BELT: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE NO. 1 ENGINE UNDER COVER See: Fluids/Engine Oil/Service and Repair/Replacement 3. REMOVE FAN AND GENERATOR V BELT (a) While turning the belt tensioner counterclockwise, align the service hole for the belt tensioner and the belt tensioner fixing position, and then insert a bar of dia 5 mm (0.197 in.) into the service hole to fix the belt tensioner in place. HINT The pulley bolt for the belt tensioner has a left-hand thread. (b) Remove the V belt. Page 3392 Information Bus: Service Precautions CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PRECAUTION 1. STEERING SYSTEM HANDLING PRECAUTIONS (a) Care must be taken when replacing parts. Incorrect replacement could affect the performance of the steering system and result in hazards when driving. 2. SRS AIRBAG SYSTEM HANDLING PRECAUTIONS (a) This vehicle is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause unexpected SRS deployment during servicing and may lead to a serious accident. Before servicing (including installation/removal, inspection and replacement of parts), be sure to read the precautionary notice for the supplemental restraint system See: Restraint Systems/Air Bag Systems/Service Precautions. 3. BUS LINE REPAIR (a) After repairing the bus line with solder, wrap the repaired part with vinyl tape See: Diagrams/Diagnostic Aids/How To Troubleshoot ECU Controlled Systems/Electronic Circuit Inspection Procedure. NOTICE: * The CANL bus line and CANH bus line must be installed together. * When installing the CAN bus lines, twist them together. * CAN bus lines are likely to be influenced by noise if the bus lines are not twisted together. * The difference in length between the CANL bus line and CANH bus line should be less than 100 mm (3.94 in.). * Leave approximately 80 mm (3.15 in.) loose in the twisted wires around the connectors. (b) Do not use by-pass wiring between the connectors. NOTICE: The feature of the twisted wire harness will be lost if by-pass wiring is used. 4. CONNECTOR HANDLING (a) When inserting tester probes into a connector, insert them from the rear of the connector. Page 6997 J/B No.3 - Instrument Panel Right Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Page 7331 Page 7025 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 6064 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Page 6077 Page 7214 Service and Repair Oil Change Reminder Lamp: Service and Repair Oil Change Reset Procedure 1. Turn the engine switch off with the trip meter A reading shown. 2. While pressing the trip meter reset button, turn the engine switch on. Without multi-information display 3. Continue to press and hold the button until the trip meter displays 000000. With multi-information display 3. Continue to press and hold the button until "MAINT REQD RESET MODE COMPLETE" appears in the display. Navigation Maintenance Item Setting (If equipped) When the navigation system is turned on, the "Information" screen displays when it is time to replace a part or certain components. 1. Push the "INFO" button. 2. Touch "Maintenance" 3. Touch the desired button. "Delete All": To cancel all conditions which have been input. "Reset All" : To reset the item which has satisfied a condition. If "ON" is selected, the system gives maintenance information with the "Information" screen when the system is turned on. If "OFF" is selected, the "Information" screen is disabled. When the vehicle needs to be serviced, the touch screen button color will change to orange. 4. Input the conditions. Notice of "Date": The next maintenance date can be input. Notice of "Distance": The driving distance until the next maintenance check can be input. "Delete": To cancel the date and distance conditions. "Reset": To reset the date and distance conditions. 5. Touch "OK" The screen returns to the "Maintenance" screen. Note: - For scheduled maintenance information, please refer to the Scheduled maintenance guide or Owners manual supplement. - Depending on your driving or the road conditions, the system may have a time-lag between the data which has been input and the actual date and driving distance. Page 8830 NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): INSTALLATION 1. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY (for 12 Speakers) (a) Connect the connector. (b) Temporarily install the speaker by aligning the positioning pins of the speaker with the instrument panel. (c) Install the speaker with the 2 bolts. NOTICE: * Do not touch the cone part of the speaker. * When installing the speaker to the instrument panel, be careful that the wires do not get caught between the parts. 2. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Attach the 6 clips and 2 claws to install the speaker panel. 3. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY RH (a) Connect the speaker connector. Page 6639 Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Page 282 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Components Oil Pressure Sender: Service and Repair Components 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: COMPONENTS Page 256 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 1136 Air Flow Meter/Sensor: Diagrams Page 6747 Driver Side J/B Inner Circuit Page 4132 Page 3814 Locations Collision Avoidance Module: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 7999 4. INSTALL LOWER NO. 2 STEERING WHEEL COVER (a) w/ Cruise Control: (1) Attach the 2 claws to install the cover. (b) w/o Cruise Control: (1) Attach the 2 claws to install the cover. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. INSPECT STEERING PAD (a) With the steering pad installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad with a new one: Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. (b) Check that the horn sounds. If the horn does not sound, inspect the horn system. 7. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Inspection Variable Valve Timing Actuator: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the camshaft timing oil control valve assembly. (c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and check the movement of the valve. OK: (d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC may be output. Page 3686 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 6811 Engine Room Main Wire Airbag System Seat Occupant Classification Module - Air Bag: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Locations Neutral Safety Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 3861 Power Steering Pressure Switch: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: REMOVAL 1. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DRAIN POWER STEERING FLUID 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the power steering oil pressure switch connector. (b) Remove the power steering oil pressure switch. (c) Remove the O-ring. Page 6214 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 9086 Connectors Part 4 Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. See: Locations Page 3834 Page 6934 Relay Box: Connector Views Engine Room R/B, J/B - Engine Compartment Left Power Steering Oil Pressure Sensor Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor Page 4217 Page 2705 Exhaust Manifold: Service and Repair Removal 1UR-FE EXHAUST: EXHAUST MANIFOLD: REMOVAL 1. REMOVE FRONT FENDER APRON SEAL RH (a) Remove the 6 clips and fender apron seal. 2. REMOVE FRONT FENDER APRON SEAL REAR RH (a) Remove the 5 clips and fender apron seal. 3. REMOVE FRONT FENDER APRON SEAL LH (a) Remove the 6 clips and fender apron seal. 4. REMOVE FRONT FENDER APRON SEAL REAR LH (a) Remove the 5 clips and fender apron seal. 5. REMOVE INTAKE MANIFOLD ASSEMBLY (a) Remove the intake manifold See: Engine/Intake Manifold/Service and Repair/Removal. 6. REMOVE GENERATOR ASSEMBLY (a) Remove the generator See: Starting and Charging/Charging System/Alternator/Service and Repair/Removal and Replacement/Removal. 7. DISCONNECT COOLER COMPRESSOR ASSEMBLY See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Removal 8. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (a) Remove the dipstick. (b) Remove the bolt and dipstick guide. (c) Remove the O-ring from dipstick guide. 9. REMOVE EXHAUST PIPE ASSEMBLY (a) for regular cab standard deck: Remove the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. (b) except regular cab standard deck: Remove the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal. 10. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 11. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR (a) Remove the 4 nuts and front floor heat insulator. Service and Repair Repairs and Inspections Required After a Collision: Service and Repair Repairs and Inspections Required After a Collision NOTICE: * Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery terminal. * For minor collisions where SRS parts do not deploy, always inspect the SRS parts. * Before performing repairs, remove airbag sensors if any kind of impact is likely to occur to an airbag sensor during repairs. * Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones. * Never disassemble or attempt to repair SRS parts. * If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one. * Use an ohmmeter/voltmeter with high impedance (10 kOhms/V minimum) for troubleshooting the electrical circuits. * Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels. * After work on the SRS is completed, perform the SRS warning light check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System * When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system. * If the vehicle is equipped with a mobile communication system, refer to the precautions. HINT In the airbag system, the center airbag sensor, front airbag sensor LH and RH, side airbag sensor LH and RH, door side airbag sensor LH and RH are collectively referred to as the airbag sensors. INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) When the airbag has not deployed, confirm the DTCs by checking the SRS warning light. If there is any malfunction in the SRS airbag system, perform troubleshooting. (b) When any of the airbags have deployed, replace the airbag sensors and check the installation condition. Page 8085 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Adjustments Parking Assist Control Module: Adjustments PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: ADJUSTMENT 1. ADJUST BUZZER VOLUME (a) Turn the knob on the clearance warning ECU to adjust the volume. Page 8254 Removal SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT SEAT ASSEMBLY Initial Inspection and Diagnostic Overview Neutral Safety Switch: Initial Inspection and Diagnostic Overview A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ON-VEHICLE INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Apply the parking brake and turn the ignition switch to ON. (b) Depress the brake pedal and check that the engine starts when the shift lever is in N or P, but does not start when the shift lever is in other positions. (c) Check that the back-up light illuminates and the reverse warning buzzer sounds when the shift lever is in R, but do not function when the shift lever is in other positions. Page 5294 SST : 09955-04100 NOTICE: Pull out the spider bearing until the SST claws contact the propeller shaft yoke. (l) Clamp the protruding universal joint spider bearing in a vise. (m)Using a brass bar and hammer, tap the propeller shaft yoke to remove the universal joint spider bearing. NOTICE: Do not tap the propeller shaft tube. HINT Use the same removal procedure for the universal joint spider bearing on the opposite side. (n) Remove the spider from the propeller shaft. 2. REMOVE NO. 1 CENTER SUPPORT BEARING ASSEMBLY (for 3 Joint Type) (a) Fix the center support bearing in a vise. (b) Using a chisel and hammer, loosen the staked part of the lock nut. Then remove the lock nut. (c) Place matchmarks on the joint yoke and shaft. (d) Using a brass bar and hammer, tap the end of the intermediate shaft to remove the joint yoke, washer and center support bearing from the intermediate shaft. 3. REMOVE REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING HINT Use the same removal procedure for both the front and rear propeller shaft universal joint spider bearings. (a) Place matchmarks on the flange yoke and shaft. Page 2065 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 938 (a) Remove the packing. (b) Remove the 6 screws and detach the 4 claws. (c) Remove the blower case (back side). (d) Remove the evaporator from the blower case (front side). 17. REMOVE NO. 1 COOLER THERMISTOR (a) Remove the No. 1 cooler thermistor. Page 3509 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH, CANL) OK -- REPLACE MAIN BODY ECU 15. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A17 skid control ECU with actuator connector. Service and Repair Cabin Air Filter: Service and Repair Step 1. Turn the engine switch off. Step 2. Open the glove box. Step 3. Remove the tray. Components Manifold Pressure/Vacuum Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: COMPONENTS Engine Controls - ECM Update For Shift Performance Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 3026 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Page 2361 Page 1837 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 4631 Spark Plug: Service and Repair Removal 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the MAF meter connector and clamp. (b) Disconnect the ventilation hose and vacuum hose. (c) Loosen the hose clamp. (d) Remove the 2 bolts and air cleaner. 3. REMOVE IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Disconnect the 3 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Remove the 4 bolts and 4 ignition coils. (b) for Bank 2: (1) Disconnect the 2 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Disconnect the engine wire harness clamp. Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Components Yaw Rate Sensor: Service and Repair Components BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS Page 2592 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 1139 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Locations Actuator: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 3052 Crankshaft Position Sensor: Diagrams Components Engine Temperature Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: COMPONENTS Page 3501 B -- REPLACE ECM A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal Short to B+ in CAN Bus Line CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short to B+ in CAN Bus Line - Short to B+ in CAN Bus Line DESCRIPTION There may be a short circuit between the CAN bus line and +B when there is resistance between terminals 6 (CANH) and 16 (BAT) or terminals 14 (CANL) and 16 (BAT) of the DLC3. HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU WIRING DIAGRAM Locations Telescoping Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Removal and Replacement Auxiliary Step / Running Board: Removal and Replacement Components EXTERIOR: SIDE STEP: COMPONENTS Page 6304 Driver Side J/B Inner Circuit Page 507 Steering Control Module: Service and Repair Installation POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION 1. INSTALL POWER STEERING ECU ASSEMBLY (a) Install the power steering ECU with the nut. Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf) (b) Connect the power steering ECU connector. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 5660 Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Connect the speed sensor connector (labeled C). NOTICE: Securely connect the connector. 4. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Installation 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Up to 11/2009 Electronic Brake Control Module: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 1966 Brake Bleeding: Service and Repair Replacement BRAKE: BRAKE FLUID: REPLACEMENT NOTICE: * Perform fluid replacement with the parking brake applied. * Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir. * Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off immediately. * Add fluid to the brake fluid reservoir as necessary so that the fluid does not decrease below the MIN level. 1. REPLACE BRAKE FLUID (a) Replace the brake fluid. (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (7) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. (10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (13)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (b) Check and bleed brake system. (1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform the following air bleed procedures. * Low pedal or spongy pedal. * Brake pedal is depressed firmly but braking is insufficient. (c) Inspect for the brake fluid leak. (d) Check and adjust brake fluid level in reservoir See: Fluids/Brake Fluid/Testing and Inspection. Page 8574 HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the front bumper. Installation PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): INSTALLATION 1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the front bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 2. INSTALL NO. 1 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. Page 528 9. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 1649 Removal WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: REMOVAL 1. REMOVE FRONT UPPER ARMREST BASE PANEL LH (a) Using a screwdriver, detach the 2 clips and 5 claws, and remove the front upper armrest base panel. Page 5638 Traction Control Switch: Service and Repair Installation BRAKE CONTROL: VSC OFF SWITCH: INSTALLATION 1. INSTALL VSC OFF SWITCH (a) Attach the 2 claws to install the VSC OFF switch into the lower instrument panel finish panel LH. (b) Connect the VSC OFF switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 8174 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2058 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 261 Page 9341 2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (a) for Steel Type Bumper: Remove the front fender splash shield. (1) Remove the 3 clips and 2 screws and fender splash shield. (b) for Resin Type Bumper: Remove the front fender splash shield. (1) Using a screwdriver, remove the pin hold clip. (2) Remove the 2 clips, 2 screws and fender splash shield. Page 4009 Air Injection Control Valve: Testing and Inspection Air Switching Valve (for Bank 2) 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): INSPECTION 1. INSPECT AIR SWITCHING VALVE ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the air switching valve. (c) Check the operation of the air switching valve. (1) Check that air does not flow from port A to port B. NOTICE: Make sure the applied pressure is 30 kPa (0.3 kgf/cm2, 4.4 psi) or less. (2) If the result is not as specified, replace the air switching valve. (3) Apply battery voltage across terminals 1 and 2. NOTICE: When applying voltage, do not touch terminals 3, 4 and 5. Page 6702 Page 4743 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 8846 Removal AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Disassembly 3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Disassembly Page 866 Engine Temperature Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the sensor. (b) Using a 19 mm ball joint lock nut wrench, install the sensor. Torque : 20 Nm (200 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench See: Service Precautions (c) Connect the sensor connector. 2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 3387 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 8542 Cellular Phone Microphone: Service and Repair Installation AUDIO / VISUAL: MICROPHONE AMPLIFIER: INSTALLATION 1. INSTALL MICROPHONE AMPLIFIER ASSEMBLY (a) Attach the 2 claws and clip to install the microphone. (b) Connect the connector. 2. INSTALL ROOF CONSOLE BOX ASSEMBLY (a) Install the roof console box See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL CAN Communication System Body Control Module: Locations CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION Page 4458 Air Flow Meter/Sensor: Diagrams Page 2507 Page 7712 Control Module HVAC: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 1077 Hazard Warning Switch: Service and Repair Installation LIGHTING: HAZARD WARNING SWITCH: INSTALLATION 1. INSTALL HAZARD WARNING SWITCH (a) Attach the 2 claws to install the switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 1212 with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 5. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (b) Connect the air fuel ratio sensor connector. (c) Connect the heated oxygen sensor connector and 2 clamps. 6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Specifications Firing Order: Specifications Firing Order 1-8-4-3-6-5-7-2 Page 7290 (c) Coat a new piston ring with power steering fluid. (d) Install the piston ring onto the power steering rack, and position it with your fingers. 2. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL (a) Coat a new cylinder tube oil seal lip with power steering fluid. (b) Using SST and a press, install the cylinder tube oil seal. SST : 09950-60010 09951-00280 09951-00480 09952-06010 SST : 09950-70010 09951-07360 NOTICE: * Make sure that the cylinder tube oil seal is installed facing in the correct direction. * Take care not to reverse the cylinder tube oil seal direction when installing. 3. INSTALL POWER STEERING RACK Page 4187 Page 6213 (a) for AC Power Supply: Connect the clamp. (b) Install the bezel with the 3 screws. 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Components OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS Page 3275 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Power Source Control ECU Power Distribution Module: Diagrams Power Source Control ECU Page 4130 Page 4216 Page 1443 Center Airbag Sensor Assembly (for Column Shift Type) Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Column Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): COMPONENTS Page 2283 Variable Valve Timing Actuator: Diagrams Page 9025 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 9218 (e) Remove the inside handle. Reassembly ENGINE HOOD / DOOR: FRONT DOOR (for Double Cab): REASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Connect the 2 cables to the inside handle. (b) Connect the connector. (c) Attach the inside handle's knob to the door trim board. (d) Attach the 9 clips to install the door trim board. (e) Install the inside handle and door trim board to the door trim panel with the screw. (f) Install the door trim board to the door panel with the screw. (g) Install the clip. 2. INSTALL FRONT DOOR ARMREST COVER LH Page 8970 Remote Switch: Service and Repair Removal AUDIO / VISUAL: STEERING PAD SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD SWITCH ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws. (c) Detach the 4 pins and remove the steering pad switch. Page 3687 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 187 Push the terminal retainer down to the temporary lock position. Page 3858 Power Steering Pressure Switch: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT POWER STEERING OIL PRESSURE SWITCH (a) Check the oil pressure switch. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch on. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering pressure. (5) Start the engine. (6) Operate the steering wheel while idling, and read the value on the Techstream. Standard: (7) If not as specified, check for DTCs See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Inspect the power steering system See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Page 944 (a) Install the motor with the 3 screws. 11. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the amplifier with the 2 screws. 12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (a) install the duct with the screw. 13. INSTALL CLEAN AIR FILTER (a) Install the filter as shown in the illustration. 14. INSTALL AIR FILTER COVER PLATE (a) Attach the 2 clips to install the plate. Page 7661 Compressor HVAC: Testing and Inspection AIR CONDITIONING: COMPRESSOR (for 1UR-FE): INSPECTION 1. INSPECT MAGNET CLUTCH ASSEMBLY (a) Check the magnet clutch operation. (1) Confirm that the magnet clutch hub and magnet clutch rotor lock when the battery positive lead is connected to terminal 3 of the magnet clutch, and the negative lead is connected to the ground wire. If the operation is not as specified, replace the magnet clutch assembly. (b) Measure the resistance. (c) Measure the resistance between terminals 1 and 2. Standard resistance: 65 to 125 Ohms at 20°C (68°F) If the resistance is not as specified, replace the cooler compressor assembly. Components Manifold Pressure/Vacuum Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: COMPONENTS Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 5721 Brake Fluid Pressure Sensor/Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 2076 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 4175 Page 6855 Multiple Junction Connector: Electrical Diagrams Junction Connector (CAN LH No.2) Inner Circuit Components Tire Pressure Module: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS Page 711 Power Seat Switch: Testing and Inspection Power Seat Switch (w/o Seat Position Memory System) SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): INSPECTION 1. INSPECT FRONT POWER SEAT SWITCH LH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Slide switch Front vertical switch Lifter switch Page 2781 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 6216 4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 8708 Page 5137 Fluid - Differential: Fluid Type Specifications Differential Oil Type ........................................................................................................................ Toyota Genuine Differential Gear Oil LT 75W-85 GL-5 or equivalent Page 185 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. A760F Automatic Transmission System Control Module: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1998 Testing and Inspection Variable Induction Control Valve: Testing and Inspection 1UR-FE INTAKE: VACUUM SWITCHING VALVE (for ACIS): ON-VEHICLE INSPECTION 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. INSPECT VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) (a) Disconnect the vacuum switching valve connector. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the vacuum switching valve assembly. (d) Check the vacuum switching valve operation. (1) When applying a vacuum to port E, check that air is sucked into the filter. (2) Apply voltage across the terminals. Page 2160 Tire Pressure Sensor: Service and Repair Disposal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire pressure warning valve and transmitter, remove the battery and dispose of it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Use the tip of a screwdriver to pry off the back cover. (b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that connect the battery to the base board. Page 2986 Power Steering Pressure Switch: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install a new O-ring to the power steering oil pressure switch. (b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch. NOTICE: * When reusing the power steering oil pressure switch, inspect the O-ring. * If the O-ring has scratches or cuts, replace the power steering oil pressure switch. (c) Using SST, install the power steering oil pressure switch. SST : 09922-10010 without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the torque wrench are connected in a straight line. (d) Connect the oil pressure switch connector. 2. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 3. ADD POWER STEERING FLUID 4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 5. INSPECT FOR POWER STEERING FLUID LEAK 6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Page 3436 Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER) OK -Continue to next step. 20. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - BUS BUFFER ECU) NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU) OK -- Continue to next step. 21. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU) NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - ECM)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU) OK -- Continue to next step. 22. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - ECM) (a) Measure the resistance according to the value(s) in the table below. Page 5283 following procedure. (a) Adjust the No. 1, No. 2 and No. 3 joint angle. (1) Support the propeller shaft with a jack. (2) Remove the 2 center bearing mounting bolts. (3) Slowly lower the jack, and disconnect the center bearing. (4) Select an appropriate center support bearing washer thickness from the table below, and obtain a washer set. Standard bearing washer thickness: HINT * Each set contains 2 washers. * Using the washer set, perform the adjustment. * As a reference when selecting a bearing washer, the angle changes as follows for every 1.0 mm (0.0394 in.) change in bearing washer thickness. Angle variation for every 1.0 mm (0.0394 in.) change in bearing washer thickness: No. 1 joint angle 0°04' (0.06°) No. 2 joint angle 0°07' (0.12°) No. 3 joint angle 0°04' (0.06°) 7. INSTALL TRANSFER HEAT INSULATOR (a) Install the heat insulator with the 3 bolts. Torque : 15 Nm (153 kgf-cm, 11 ft-lbf) 8. INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY Page 9087 Trailer Lamps: Testing and Inspection LIGHTING: LIGHTING SYSTEM: PROBLEM SYMPTOMS TABLE HINT * Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. * Inspect the fuses and relays related to this system before inspecting the suspected areas below. Page 9208 3. INSTALL COURTESY LIGHT ASSEMBLY (a) Attach the claw to install the courtesy light. (b) Connect the connector. 4. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Front Door Speaker (for Double Cab)/Installation 5. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (a) Attach the 3 clips to install the front lower door frame bracket garnish. 6. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Install the power window regulator master switch with the 3 screws. 7. INSTALL FRONT UPPER ARMREST BASE PANEL LH (a) Connect the connectors. Page 4921 (a) Apply MP grease to the shifting bellcrank as shown in the illustration. (b) Install the shifting bellcrank with the bolt. Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) Disassembly A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): DISASSEMBLY 1. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Using a thin-bladed screwdriver, release the connector housing retainer. (b) Using a thin-bladed screwdriver, push out terminals 4 (ILL+) and 8 (ILL-) from the rear as shown in the illustration. (c) Rotate the indicator light wire counterclockwise to align the wire with the key part of the transmission floor shift assembly and remove the wire. Power Source Control ECU Power Distribution Module: Diagrams Power Source Control ECU Page 8985 (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY Page 8986 (a) Detach the 4 clips. (b) Disconnect the connector and remove the panel. 11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE (a) Detach the 2 claws and remove the sensor. Installation THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE (a) Attach the 2 claws to install the sensor. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY Page 3238 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 908 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL AMBIENT TEMPERATURE SENSOR (a) Attach the clamp to install the ambient temperature sensor. (b) Connect the connector. Components Actuator: Service and Repair Components DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): COMPONENTS Page 7104 Tire Pressure Module: Diagrams Page 4314 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 7720 (a) for Manual Air Conditioning System: Disconnect the 2 connectors. (b) for Automatic Air Conditioning System: Disconnect the 3 connectors. (c) Remove the 2 screws and amplifier. Page 7439 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Install the receiver with the bolt. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the receiver connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 8391 Page 3364 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. Page 4041 Air Injection Pump: Service and Repair Removal 1UR-FE EMISSION CONTROL: AIR PUMP: REMOVAL 1. DISCONNECT FRONT FENDER LINER RH (a) Remove the 8 clips, disconnect the fender liner. 2. DISCONNECT FRONT FENDER APRON SEAL RH (a) Using a clip remover, remove the 2 clips and fold back the fender apron seal. 3. REMOVE NO. 2 AIR INJECTION SYSTEM HOSE (a) Engine Room Side: (1) Disconnect the 2 clamps. (2) Disconnect the No. 2 air injection system hose. (3) Using a clip remover, remove the clamp from the body panel. (b) Front Fender RH Inside: (1) Disconnect the clamp. (2) Disconnect the No. 2 air injection system hose from the air pump. 4. REMOVE NO. 3 AIR INJECTION SYSTEM HOSE (a) Engine Room Side: Up to 11/2009 Hydraulic Fluid Regulator: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Radiator Cooling Fan: Service and Repair Components 1UR-FE COOLING: FAN: COMPONENTS Specifications Fuel Pressure: Specifications FUEL PRESSURE Page 6066 Ignition Switch: Connector Views Page 8924 Hood Sensor/Switch (For Alarm): Diagrams Page 6208 Installation OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION 1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply) (a) Attach the 2 claws to install the power outlet socket. 2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard) (a) Attach the 2 claws to install the power outlet socket cover. 3. INSTALL REAR POWER OUTLET SOCKET (for Standard) (a) Attach the claw to install the power outlet socket. 4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL Page 397 HINT The wavelength becomes shorter as the vehicle speed increases. (k) WAVEFORM 10: HINT The duty ratio varies depending on the throttle actuator operation. (l) WAVEFORM 11: HINT The duty ratio varies depending on the throttle actuator operation. (m)WAVEFORM 12: Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6164 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Engine Immobiliser System Alarm Module: Locations Engine Immobiliser System ENGINE IMMOBILISER: ENGINE IMMOBILISER SYSTEM: PARTS LOCATION Page 8410 Seat Position Sensor: Testing and Inspection SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: ON-VEHICLE INSPECTION 1. CHECK SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If there are any defects as mentioned below, replace the seat position sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. CAUTION: For removal and installation procedures of the seat position sensor, be sure to follow the correct procedure. Page 4027 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 3835 Engine Bank Identification Page 1695 for CrewMax of standard deck Page 5201 (d) Grind the rear axle bearing inner race surface using a grinder, then remove it with a chisel. 3. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY (a) Temporarily install 4 nuts to the housing bolts. NOTICE: Do not use any nuts removed from the vehicle, as they may be damaged. (b) Using a hammer, remove the 4 housing bolts and rear axle hub and bearing. (c) Remove the nuts. 4. REMOVE BRAKE DRUM OIL DEFLECTOR (a) Using SST, remove the 5 hub bolts. SST : 09650-17011 (b) Remove the deflector and deflector gasket from the rear axle shaft. Reassembly AXLE: REAR AXLE SHAFT: REASSEMBLY NOTICE: Do not allow foreign matter, etc. to contact the ABS rotor bearing. 1. INSTALL BRAKE DRUM OIL DEFLECTOR (a) Install a new deflector gasket and deflector to the rear axle shaft. Page 1345 Page 6502 Engine Room R/B And Engine Room J/B Inner Circuit Page 219 (1) Measure the resistance according to the value(s) in the table below. Standard resistance: (2) If the result is not as specified, replace the HORN fuse. (b) Measure the resistance of the horn relay circuit. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: (2) If the result is not as specified, replace the integration relay. 4. INSTALL INTEGRATION RELAY (UNIT E) (a) Connect the 3 connectors. (b) Install the integration relay to the engine room relay block. (c) Install the engine room relay block cover. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning Page 6691 Fuse Block Location - Under The Instrument Panel Fuse Location - Under The Instrument Panel Page 7211 Steering Column Control Module: Diagrams Page 912 Cabin Temperature Sensor / Switch: Diagrams Page 4320 Air Flow Meter/Sensor: Diagrams Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5952 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 7742 (1) Insert the pin into the plate groove. (2) Attach the claw to install the main plate. (3) Install the 2 screws. (c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the damper servo. (d) Install the 4 screws and connect the 2 connectors. 9. INSTALL AIR DUCT (a) Install the duct with the 2 screws. 10. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY Page 8328 Page 6844 Page 6906 Relay Box: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 1435 Page 934 (a) Remove the filter. 6. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (a) Remove the screw and duct. 7. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Remove the 2 screws and amplifier. 8. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY (a) Remove the 3 screws and motor. 9. REMOVE AIR DUCT (a) Remove the 2 screws and duct. Page 3445 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU) OK -- Continue to next step. 12. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR) (a) Disconnect the J83 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR) Page 8949 Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Rear Side) Components PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): COMPONENTS Page 183 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 6411 Multiple Junction Connector: Electrical Diagrams Junction Connector (CAN LH No.2) Inner Circuit Page 9070 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 3547 2. CHECK FOR OPEN IN CAN BUS WIRE (MAIN BODY ECU BRANCH WIRE) (a) Disconnect the J2 main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE MAIN BODY ECU BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Disconnect the DA, DB and DD main body ECU connectors. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: (d) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 6738 Driver Side J/B - Cowl Side Left Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Bypass Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 9277 Hood Shock / Support: Service and Repair Disposal ENGINE HOOD / DOOR: HOOD SUPPORT: DISPOSAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. DISPOSE OF HOOD SUPPORT ASSEMBLY (a) Horizontally fix the hood support in a vise with the piston-rod pulled out. (b) Wear safety glasses. Gradually cut a part between A and B shown in the illustration using a metal saw and gradually release the gas. CAUTION: Be careful when drilling because shards of metal may fly about. Always use the proper safety equipment. NOTICE: The gas is colorless, odorless and nonpoisonous. Page 3262 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 6040 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 6336 Engine - Snow Ingestion Into Air Cleaner Box Front Fender Liner: By Symptom Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 4591 Push the terminal retainer down to the temporary lock position. Locations Ambient Light Sensor: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 2370 (3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. (4) Pinch the connector and disconnect the connector and pipe. (5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out. NOTICE: Do not use any tools. (6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. (7) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag. (e) Observe these precautions when connecting the fuel tube connector (for Quick Type). (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe. (3) After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected. Page 2081 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 8127 Seat Occupant Classification Module - Air Bag: Testing and Inspection SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: ON-VEHICLE INSPECTION 1. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the ECU. CAUTION: * For removal and installation procedures of the occupant classification ECU, be sure to follow the correct procedure. * If the airbags have deployed, replace the occupant classification ECU on the side in which the collision occurred. Replace both if necessary. Page 1986 Page 7581 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 6994 Driver Side J/B - Cowl Side Left Page 6840 Diagrams Brake Fluid Level Sensor/Switch: Diagrams Page 1091 Headlamp Dimmer Switch: Testing and Inspection LIGHTING: HEADLIGHT DIMMER SWITCH: INSPECTION 1. INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Check the light control switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: (2) If the result is not as specified, replace the headlight dimmer switch. (b) Check the headlight dimmer switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: (2) If the result is not as specified, replace the headlight dimmer switch. HINT Perform the "LOW BEAM" and "HI BEAM" inspection with the light control switch on "HEAD". (c) Check the turn signal switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: (2) If the result is not as specified, replace the headlight dimmer switch. Page 8375 Locations Engine Temperature Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 287 Page 6720 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 286 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 4138 Page 6593 "Case2" 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 5072 Standard Drive Pinion Preload Plus: (b) If necessary, disassemble and inspect the differential. 22. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (a) Remove the bearing retainer and differential case. (b) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue. (c) Install the differential case to the differential carrier. (d) Install the differential cross shaft bearing retainer and front differential front support assembly LH with the 14 bolts. for bolt A - Torque : 65 Nm (633 kgf-cm, 48 ft-lbf) for bolt B - Torque : 155 Nm (1581 kgf-cm, 114 ft-lbf) (e) Hold the companion flange firmly and rotate the ring gear in both directions. (f) Remove the differential case, side bearing retainer and differential case. (g) Inspect the tooth contact pattern. Page 3474 Page 7671 Compressor washer thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) NOTICE: Adjustment should be performed with 3 or fewer magnet clutch washers. (e) Remove the cooler compressor from the vise. Page 2052 Page 1838 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 73 Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS Page 189 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Components Manifold Pressure/Vacuum Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: COMPONENTS Removal and Replacement Brake Master Cylinder: Removal and Replacement Components BRAKE: BRAKE MASTER CYLINDER: COMPONENTS Page 4035 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 6401 Page 5186 (a) Install a new snap ring to the inboard joint shaft. (b) Coat the spline of the inboard joint shaft assembly with gear oil. (c) Align the shaft splines and install the drive shaft with a brass bar and hammer. NOTICE: * Set the snap ring with the opening side facing downward. * Be careful not to damage the oil seal. HINT Whether the inboard joint shaft is in contact with the pinion shaft or not can be confirmed from the sound or feeling when driving it. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for Axle Hub Side) (a) Install the drive shaft to the steering knuckle. NOTICE: Be careful not to damage the oil seal, boots and dust seal. 3. CONNECT FRONT LOWER BALL JOINT ATTACHMENT See: Steering and Suspension/Suspension/Control Arm/Service and Repair/Removal and Replacement/Front Lower Suspension Arm/Installation 4. INSTALL TIE ROD END SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Removal and Replacement/Installation 5. INSTALL AXLE HUB NUT See: Wheel Hub/Service and Repair/Removal and Replacement/Installation 6. INSTALL FRONT AXLE HUB GREASE CAP See: Wheel Hub/Service and Repair/Removal and Replacement/Installation 7. INSTALL FRONT SPEED SENSOR LH (a) Install the front speed sensor See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Speed Sensor/Installation. 8. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 9. INSTALL FRONT WHEEL (a) Install the front wheels. for aluminum wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for steel wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 10. ADD DIFFERENTIAL OIL See: Differential Assembly/Fluid - Differential/Service and Repair 11. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. 12. CHECK FOR DIFFERENTIAL OIL LEAK 13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Page 2406 Removal 1UR-FE LUBRICATION: ENGINE OIL COOLER: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. DRAIN ENGINE OIL See: Engine Oil/Service and Repair/Replacement 3. DRAIN ENGINE COOLANT See: Cooling System/Coolant/Service and Repair 4. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement 5. REMOVE FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 6. REMOVE OIL FILTER ELEMENT See: Engine Oil/Service and Repair/Replacement 7. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY See: Oil Pressure Sender/Service and Repair/Removal 8. DISCONNECT COOLER COMPRESSOR ASSEMBLY See: Oil Pump/Service and Repair/Removal and Replacement/Removal 9. REMOVE WATER BY-PASS PIPE See: Water Pump/Service and Repair/Removal 10. REMOVE NO. 1 OIL COOLER BRACKET (a) Remove the 2 nuts and bracket. Locations Telescoping Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Page 6159 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 1978 Driver Side J/B - Cowl Side Left Page 7844 Cabin Temperature Sensor / Switch: Service and Repair Removal AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE ROOM TEMPERATURE SENSOR Locations Starter Motor: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 3808 Engine Temperature Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm ball joint lock nut wrench, remove the sensor. (c) Remove the gasket from the sensor. Page 8257 (a) Align the vehicle's claws with the seat belt retractor positioning holes. (b) Install the seat belt with the 2 bolts. HINT First install bolt A, and then install bolt B. for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) for bolt B - Torque : 43 Nm (428 kgf-cm, 31 ft-lbf) (c) Connect the pretensioner connector as shown in the illustration. (d) Insert the bolt and extension of the anti-rotation device through the quarter trim panel hole into the vehicle body. (e) Install the seat belt's shoulder anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (f) Attach the 2 claws to close the seat belt anchor cover. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY Air Conditioning System (for Automatic Air Conditioning System) Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Component Tests and General Diagnostics Garage Door Opener Transmitter: Component Tests and General Diagnostics GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: ON-VEHICLE INSPECTION 1. INSPECT GARAGE DOOR OPENER (a) Press each switch and check that the red LED turns on. If one or more of the switches does not turn on the LED, confirm normal operation of the fuse and wire harness. If the fuse and wire harness are malfunctioning, replace them. If not, replace the garage door opener. 2. INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTING HINT Use the "HomeLink" tester and a tester transmitter for this test. First erase the customer's transmitter code, and then register the tester transmitter code. (a) Check if the tester transmitter code was successfully registered. HINT If the code cannot be registered, replace the garage door opener. (b) Press the garage door opener switch that was registered to the tester transmitter. Check if the "HomeLink" tester's green LED illuminates. HINT If the green LED does not illuminate, replace the garage door opener. (c) When the inspection is complete, reregister the customer's transmitter code(s) again. Page 1602 Four Wheel Drive Selector Switch: Testing and Inspection JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION 1. INSPECT 4WD CONTROL SWITCH (a) Check the harness and connector (ECU - battery and body ground). (1) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage: (2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning, repair or replace harness or connector. If the harness or connector is normal, replace the 4WD control ECU See: Powertrain Management/Transmission Control Systems/Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. Standard resistance: (3) If there is a malfunction, repair or replace the harness or connector. (b) Check the harness and connector (switch - ECU). (1) Disconnect the A25 ECU connector. (2) Disconnect the L1 switch connector. (3) Measure the resistance according to the value(s) in the table below. Page 6380 Page 8843 (a) Using a screwdriver, detach the 4 clips and claw. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 5. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Using a screwdriver, detach the 4 clips and claw. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY LH (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. NOTICE: Do not touch the cone part of the speaker. 7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY RH Page 2280 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 7389 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 2870 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 527 Tire Pressure Module: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the ECU with the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the ECU connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 7. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration. 8. PERFORM INITIALIZATION (a) Perform initialization See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. Locations Transmission Temperature Sensor/Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1931 Fluid - Transfer Case: Service and Repair JF1A TRANSFER: TRANSFER OIL: REPLACEMENT 1. DRAIN TRANSFER OIL (a) Remove the 4 bolts and lower transfer case protector. (b) Remove the filler plug and gasket. (c) Remove the drain plug and gasket, and drain the transfer oil. 2. ADD TRANSFER OIL (a) Install a new gasket and the drain plug. Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) (b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole. NOTICE: * Pour oil slowly. * Pour oil a little at a time, waiting several minutes between each addition of oil. (c) Wait approximately 5 minutes and check that the oil level has not changed. (d) Install a new gasket and the filler plug. Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) (e) Install the lower transfer case protector with the 4 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) Page 3565 (b) Measure the resistance according to the value(s) in the table below. 12. CHECK POWER STEERING ECU HINT For vehicles with a power steering ECU only. (a) Disconnect the J101 ECU connector. (b) Measure the resistance according to the value(s) in the table below. 13. CHECK 4WD CONTROL ECU HINT For vehicles with 4WD only. (a) Disconnect the A25 and A26 ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Page 9101 Page 7038 for Double Cab of Long Deck Page 5435 Seals and Gaskets: Service and Repair Front Oil Seal Components JF1A TRANSFER: TRANSFER CASE FRONT OIL SEAL: COMPONENTS Replacement JF1A TRANSFER: TRANSFER CASE FRONT OIL SEAL: REPLACEMENT 1. DRAIN TRANSFER OIL See: Fluid - Transfer Case/Service and Repair Page 6845 Page 792 Parking Brake Warning Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 7048 Standard difference: 0 +/-1 mm (0 +/-0.0394 in.) or less (e) Tighten the tie rod end lock nuts. Torque : 82 Nm (836 kgf-cm, 60 ft-lbf) (f) Place the boots on the seats and install the clips. HINT Make sure that the boots are not twisted. 5. INSPECT WHEEL ANGLE (a) Turn the steering wheel to the left and right full lock positions, and measure the turning angle. Standard wheel angle (unloaded vehicle): for Regular Cab of Standard Deck Standard wheel angle (unloaded vehicle): for Regular Cab of Long Deck Page 854 Page 8457 Alarm Module: Diagrams Glass Breakage Sensor ECU Page 5444 Standard voltage: (3) If the voltage is not as specified, replace the 4WD control ECU See: Control Module/Service and Repair/Removal. If the voltage is normal, replace the 4WD control switch. Page 6596 Push the terminal retainer down to the temporary lock position. Components Auxiliary Power Outlet Switch: Service and Repair Components OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS Page 8353 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: MIL Circuit - MIL Circuit DESCRIPTION The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunction detections by the ECM. When the ignition switch is turned to ON, power is supplied to the MIL circuit, and the ECM provides the circuit ground which illuminates the MIL. The MIL operation can be checked visually: When the ignition switch is first turned to ON, the MIL should be illuminated and should then turn off when the engine is started. If the MIL remains illuminated or is not illuminated, conduct the following troubleshooting procedure using the Techstream. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. CHECK THAT MIL IS ILLUMINATED (a) Perform troubleshooting in accordance with the table below. Result B -- CHECK THAT MIL IS ILLUMINATED A -- Continue to next step. 2. CHECK WHETHER MIL TURNS OFF (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. (c) Turn the Techstream on. Page 1140 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 4595 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 4700 Transmission Speed Sensor: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL 1. REMOVE SPEED SENSOR NT (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. 2. REMOVE SPEED SENSOR SP2 (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. Page 3386 Page 1644 Tape the screwdriver tip before use. (b) Remove the regulator switch. Installation WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: INSTALLATION 1. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Attach the 2 claws to install the regulator switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 6245 Specifications Brake Pad: Specifications FRONT BRAKE PAD LINING THICKNESS Standard thickness............................................................................................................................... ......................................................11.9 mm (0.469 in.) Minimum thickness............................................................................................................................... ....................................................1.0 mm (0.0394 in.) REAR BRAKE PAD LINING THICKNESS Standard thickness............................................................................................................................... ......................................................12.0 mm (0.472 in.) Minimum thickness............................................................................................................................... ....................................................1.0 mm (0.0394 in.) Page 8089 Impact Sensor: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 1654 HINT Tape the screwdriver tip before use. (b) Disconnect the connector. 2. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Detach the 2 claws and remove the regulator switch. Installation WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Attach the 2 claws to install the regulator switch. 2. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH (a) Connect the connector. Page 8491 2. REMOVE REAR DOOR SCUFF PLATE RH (a) Detach the 8 claws and 2 clips, and remove the scuff plate. 3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 5. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. INSTALL REAR DOOR SCUFF PLATE RH Page 5568 (1) Keep the vehicle stationary on a level surface for 1 second or more. HINT * The zero point calibration is performed only once after the system enters test mode. * Calibration cannot be performed again until the stored data is cleared once. (2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased. (3) Turn the ignition switch off. 6. PERFORM INITIALIZATION OF STEERING ANGLE SENSOR NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will become misaligned. (a) Check that the steering wheel is in the centered position. (b) Disconnect the negative battery terminal for more than 2 seconds. NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. (c) Reconnect the negative battery terminal. Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 3327 HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor. (b) WAVEFORM 1: Page 6556 J/B No.6 Assembly - Instrument Panel Center Page 5563 Acceleration/Deceleration Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 9136 Trailer Towing Part 4 Airbag Cut-OFF Switch Air Bag Deactivation Switch: Testing and Inspection Airbag Cut-OFF Switch SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSPECTION 1. INSPECT AIRBAG CUT-OFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 2819 Page 749 Seat Memory Switch: Service and Repair Installation SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSTALLATION 1. INSTALL SEAT MEMORY SWITCH (a) Install the seat memory with the 2 screws. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL FRONT DOOR ARMREST COVER LH 4. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly Page 5767 (a) Install the clamp with the bolt (labeled A). Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) (b) Install the No. 2 parking brake cable to the rear axle carrier with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (c) Connect the No. 2 parking brake cable to the intermediate lever (labeled B) and install the 5 bolts (labeled C and D). NOTICE: Do not bend and twist the parking brake cable. for bolt C - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) for bolt D - Torque : 14 Nm (138 kgf-cm, 10 ft-lbf) (d) Connect the No. 2 parking brake cable to the 2 clamps (labeled E). 14. INSTALL NO. 2 CABLE RETAINER (a) Install the retainer with the bolt. Components Solar Sensor: Service and Repair Components AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): COMPONENTS Page 7616 Cabin Temperature Sensor / Switch: Testing and Inspection AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): INSPECTION 1. INSPECT ROOM TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the thermistor. NOTICE: * Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. * When measuring the resistance, the sensor temperature must be the same as the ambient temperature. Page 1312 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Page 6542 Locations Transmission Temperature Sensor/Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 7942 (f) Place the tires. NOTICE: Do not place the deployment direction of the curtain shield airbag facing the ground. (1) Place at least 2 tires under the tire which the curtain shield airbag is tied to. (2) Place at least 2 tires over the tire which the curtain shield airbag is tied to. The top tire should have the disc wheel installed. NOTICE: * Do not place SST connector under the tire because it could be damaged. * As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. * As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (3) Tie the tires together with 2 wire harnesses. NOTICE: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (g) Install SST. Page 793 Parking Brake Warning Switch: Diagrams Page 2726 HINT Install the monolithic converter protector within the angle range specified in the illustration. 2. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1) (a) Install the 4 No. 1 converter protector stays. (b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) HINT Install the monolithic converter protector within the angle range specified in the illustration. 3. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. (b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) HINT Install the monolithic converter protector within the angle range specified in the illustration. 4. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Install the 4 No. 1 converter protector stays. Page 4992 A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID See: Wiring Harness/Service and Repair/Removal 2. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY See: Wiring Harness/Service and Repair/Removal 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY See: Wiring Harness/Service and Repair/Removal 4. DISCONNECT TRANSMISSION WIRE See: Wiring Harness/Service and Repair/Removal 5. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the bolt, detent spring cover and detent spring. (b) Remove the 19 bolts and valve body. (c) Remove the check ball body and spring. NOTICE: Do not drop the check ball body and spring. Installation A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION 1. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Install the spring and check ball body. (b) Align the hole of the manual valve with the pin of the lever and connect the pin to the manual valve. Page 3622 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS Removal 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL CAUTION: * The procedures should be performed by at least 2 people. * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Disconnect the sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Disconnect the heated oxygen sensor connector and 2 clamps. Transmission Control Cable (for Column Shift Type) Shift Cable: Service and Repair Transmission Control Cable (for Column Shift Type) Components A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Column Shift Type): COMPONENTS Removal A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Column Shift Type): REMOVAL Page 5154 1. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair 2. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Remove the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Removal and Replacement/Front Drive Shaft Assembly/Removal. 3. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, tap out the 2 oil seals. SST : 09308-10010 4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Apply MP grease to 2 new oil seals. (b) Using SST and a hammer, tap in the 2 oil seals. SST : 09550-00032 SST : 09950-70010 09951-07100 NOTICE: Make sure the LH and RH oil seals are installed in the proper locations. Standard oil seal depth: 5. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (a) Install the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Removal and Replacement/Front Drive Shaft Assembly/Installation. 6. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair Page 3354 Page 1942 (g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap. NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap. (h) Install the oil filter drain plug. Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Be careful that the O-ring does not get caught between any surrounding parts. 5. ADD ENGINE OIL (a) Add fresh oil. Standard Oil Grade (for USA): Standard Oil Grade (for Canada): Standard Oil Capacity: (b) Install the oil filler cap. 6. INSPECT FOR OIL LEAK (a) Start the engine. Make sure that there are no oil leaks from the area that was worked on. 7. CHECK ENGINE OIL LEVEL See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Testing and Inspection 8. INSTALL NO. 1 ENGINE UNDER COVER Page 6999 J/B No.5 - Instrument Panel Center Page 8362 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 2408 (b) Remove the gasket. Installation 1UR-FE LUBRICATION: ENGINE OIL COOLER: INSTALLATION 1. INSTALL OIL COOLER SPACER (a) Apply a light coat of engine oil to a new gasket. (b) Install the gasket to the oil cooler spacer. (c) Install the oil cooler spacer to the oil filter bracket with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. INSTALL OIL COOLER ASSEMBLY (a) Apply a light coat of engine oil to 2 new O-rings. (b) Install the 2 O-rings to the oil cooler. Page 6393 Page 1981 Page 6506 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 9078 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 5619 Page 5874 Parking Brake Warning Switch: Service and Repair Reassembly PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY 1. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the switch with the screw. Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf) Page 4634 (4) Connect the engine wire harness clamp. 3. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts. Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Tighten the hose clamp. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) (c) Connect the ventilation hose and vacuum hose. (d) Connect the MAF meter connector and clamp. 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 5371 Four Wheel Drive Selector Switch: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE 4WD CONTROL SWITCH (a) Detach the 3 claws to remove the switch. Page 6932 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 6180 3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 5. REMOVE CENTER FRONT SEAT ASSEMBLY (a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal. 6. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Disconnect the power outlet socket connector. (b) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 7. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. Page 4666 Shift Interlock Control Module: Diagrams Page 8572 Page 5589 Braking Sensor/Switch: Diagrams Page 3906 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Page 526 Tire Pressure Module: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL NOTICE: * It is necessary to perform initialization See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. * When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU using the intelligent tester or Techstream and write them down before removal. 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the ECU connector. (b) Remove the 2 nuts and ECU. Page 3733 HINT The wavelength becomes shorter as the engine rpm increases. (f) WAVEFORM 5: HINT * The wavelength becomes shorter as the engine rpm increases. * The waveforms and amplitudes displayed differ slightly depending on the vehicle. (g) WAVEFORM 6: HINT The wavelength becomes shorter as engine rpm increases. (h) WAVEFORM 7: Components Engine Control Module: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS Page 2828 HINT The wavelength becomes shorter as the engine rpm increases. (n) WAVEFORM 13: HINT The waveform varies depending on the CAN communication signal. (o) WAVEFORM 14: HINT The waveform varies depending on the CAN communication signal. (p) WAVEFORM 15: HINT The wavelength becomes shorter as the engine rpm increases. Page 4274 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 180 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Components Integrated Accessory Switch Assembly: Service and Repair Components METER: DRIVE MONITOR SWITCH: COMPONENTS Page 4589 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 244 Power Distribution Module: Service and Repair Removal OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 6. REMOVE VOLTAGE INVERTER ASSEMBLY (a) Remove the 2 bolts. (b) Disconnect the voltage inverter connector and removal the voltage inverter. Page 8675 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 7316 NOTICE: If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 5. CONNECT SKID CONTROL SENSOR WIRE (a) Connect the sensor wire to the steering knuckle and upper arm with the 2 bolts. for Bolt A - Torque : 13 Nm (133 kgf-cm, 10 ft-lbf) for Bolt B - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) 6. TEMPORARILY INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING LH See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation 7. STABILIZE SUSPENSION See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation 8. TIGHTEN FRONT SUSPENSION UPPER ARM ASSEMBLY LH (a) Tighten the nut. Torque : 235 Nm (2396 kgf-cm, 173 ft-lbf) 9. TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation 10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair. 11. INSTALL FRONT WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) Components SUSPENSION: FRONT LOWER SUSPENSION ARM: COMPONENTS Page 821 Traction Control Switch: Service and Repair Removal BRAKE CONTROL: VSC OFF SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE VSC OFF SWITCH (a) Disconnect the VSC OFF switch connector. (b) Using a screwdriver, detach the 2 claws and remove the VSC OFF switch from the lower instrument panel finish panel LH. Page 7460 Tire Pressure Warning Reset Switch: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING RESET SWITCH (a) Attach the 2 claws to install the reset switch. (b) Connect the switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Components Seat Position Sensor: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: COMPONENTS Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Page 6351 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 1816 ^ 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 Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT Standard............................................................................................................................................... ........................................600 +/-30 g (21.2 +/-1.1 oz.) Page 8790 Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 3. INSPECT FRONT NO. 4 SPEAKER ASSEMBLY (for 12 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Instrument Panel Speaker (for Double Cab) AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): INSPECTION 1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for Standard) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 10 Speakers) Page 8086 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Page 6698 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 9297 Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power Source Circuit DESCRIPTION When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil, closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and +B2 of the ECM. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN) Page 3082 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 7766 8. INSTALL NO. 2 COOLER COVER (a) Attach the 2 claws to install the cover. (b) Install the 2 nuts. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Check Mode Procedure. 11. ADD ENGINE COOLANT (a) for 1GR-FE: Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. (b) for 1UR-FE: Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. (c) for 3UR-FE: Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. (d) for 3UR-FBE: Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. 12. CHARGE REFRIGERANT See: Service and Repair 13. WARM UP ENGINE See: Service and Repair 14. CHECK FOR ENGINE COOLANT LEAK See: Service and Repair 15. CHECK FOR REFRIGERANT GAS LEAK (a) Check for refrigerant gas leak See: Service and Repair. Specifications Brake Rotor/Disc: Specifications FRONT BRAKE DISC THICKNESS Standard thickness............................................................................................................................... ........................................................32.0 mm (1.26 in.) Minimum thickness............................................................................................................................... ......................................................29.0 mm (1.14 in.) DISC RUNOUT Maximum disc runout........................................................................................................................... .................................................0.05 mm (0.00197 in.) REAR BRAKE DISC THICKNESS Standard thickness............................................................................................................................... ......................................................18.0 mm (0.709 in.) Minimum thickness............................................................................................................................... ....................................................16.0 mm (0.630 in.) DISC RUNOUT Maximum disc runout........................................................................................................................... ...................................................0.2 mm (0.00787 in.) Page 8850 Up to 11/2009 AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 4. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 6. REMOVE REAR DOOR ARMREST COVER LH 7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 8. REMOVE REAR NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. Page 6607 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Components Tire Pressure Monitor Receiver / Transponder: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS Page 588 Integrated Accessory Switch Assembly: Service and Repair Installation METER: DRIVE MONITOR SWITCH: INSTALLATION 1. INSTALL DRIVE MONITOR SWITCH (a) Attach the 2 claws to install the monitor switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 7882 Refrigerant Pressure Sensor / Switch: Service and Repair Removal AIR CONDITIONING: PRESSURE SWITCH: REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair 2. REMOVE PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the switch. (c) Remove the O-ring from the pressure switch. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Page 8277 Engine Controls - ECM Update For Shift Performance Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. A/C Amplifier, A/C Blower Assembly Control Module HVAC: Diagrams A/C Amplifier, A/C Blower Assembly Page 7883 Refrigerant Pressure Sensor / Switch: Service and Repair Installation AIR CONDITIONING: PRESSURE SWITCH: INSTALLATION 1. INSTALL PRESSURE SWITCH (a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pressure switch. Compressor oil: ND-OIL 8 or equivalent (b) Install the O-ring on the pressure switch. (c) Install the switch. Torque : 10.8 Nm (110 kgf-cm, 8 ft-lbf) (d) Connect the connector. 2. CHARGE REFRIGERANT See: Service and Repair 3. WARM UP ENGINE See: Service and Repair 4. CHECK FOR LEAKAGE OF REFRIGERANT See: Service and Repair Page 4632 (4) Remove the 2 bolts and disconnect the water by-pass pipe. (5) Remove the 4 bolts and 4 ignition coils. 4. REMOVE SPARK PLUG (a) Using a 16 mm plug wrench, remove the 8 spark plugs. Page 5886 Page 1430 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY Page 8373 Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): COMPONENTS Page 6392 Junction Connector Page 5059 SST : 09950-60010 09951-00550 SST : 09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04061 09957-04010 09958-04011 HINT Fix the claws of SST into the notch in the differential case assembly. 21. DISASSEMBLE DIFFERENTIAL CASE (a) Using a pin punch and hammer, tap out the straight pin. (b) Remove these parts from the differential case assembly. (1) 2 differential side gears (2) 2 differential side gear thrust washers (3) Differential pinion shaft (4) 2 differential pinion gears (5) 2 differential pinion gear thrust washers 22. INSPECT DIFFERENTIAL GEAR KIT (a) Check that there is no damage to the pinion gear and side gear. If the pinion gear and/or side gear is damaged, replace the differential gear kit. 23. INSPECT FRONT DIFFERENTIAL CASE Page 4931 (a) Move the shift lever to N. (b) Fold back the floor carpet. (c) Disconnect the column shift transmission control cable end from the column shift. (d) Press the sides of the outer cable socket to detach the claws and disconnect the cable from the steering column shaft bracket. (e) Remove the 2 bolts and disconnect the 2 cable clamps. (f) Remove the nut and clip, and disconnect the transmission control cable from the automatic transmission. (g) Remove the nut and disconnect the transmission control cable support. Page 2823 HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor. (b) WAVEFORM 1: Page 2082 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Locations Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 6340 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 6385 Locations Seat Belt Buckle Switch: Locations SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Specifications Firing Order: Specifications Firing Order 1-8-4-3-6-5-7-2 Page 4190 IV. Background There is a possibility that certain accelerator pedal mechanisms may in rare instances mechanically stick in a partially depressed position or return slowly to the idle position. Over time some accelerator pedal mechanisms may become worn. As a result of this wear combined with certain operating and environmental conditions friction in the mechanism may increase and intermittently result in the accelerator pedal being hard to depress slow to return or in the worst case stick in a partially open position. Page 6325 JQ1-LJ1 Locations Overdrive Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 4593 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 850 Yaw Rate Sensor: Diagrams Page 3316 (a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE OK -- Continue to next step. 2. INSPECT RELAY (IG2, EFI) (a) Remove the integration relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 7163 Tire Pressure Warning Reset Switch: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING RESET SWITCH (a) Attach the 2 claws to install the reset switch. (b) Connect the switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 1389 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Front Power Window Switch Power Window Switch: Diagrams Front Power Window Switch Page 6610 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 1320 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 2291 Variable Valve Timing Actuator: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION 1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) Front Axle Hub Bolt Wheel Fastener: Service and Repair Front Axle Hub Bolt Components AXLE: FRONT AXLE HUB BOLT: COMPONENTS Replacement AXLE: FRONT AXLE HUB BOLT: REPLACEMENT HINT * Use the same procedures for the LH side and RH side. Page 6903 Page 4513 Crankshaft Position Sensor: Diagrams Page 6582 Page 6360 Page 4578 Page 3295 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 3620 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. (c) for 2WD: Connect the air fuel ratio sensor connector. 2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Connect the front No. 2 exhaust pipe to the exhaust pipe support. (b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (c) Connect the air fuel ratio sensor connector. (d) Connect the heated oxygen sensor connector. 3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) Locations Dimmer Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Components Power Distribution Module: Service and Repair Components OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS Diagram Information and Instructions Relay Box: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 1553 Tire Pressure Sensor: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so that the print surface can be seen. NOTICE: * Check that there is no visible deformation, damage or other abnormalities on the tire pressure warning valve and transmitter. * Check that there is no foreign matter on the inner grommet and around the rim hole. * If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be damaged or fail to transmit signals when running at a high speed. * If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before installation. * The transmitter ID registration must be performed for all tire pressure warning valve and transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do not need to be replaced before performing the transmitter ID registration See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration * It is necessary to perform initialization See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been replaced. (b) If reusing the tire pressure warning valve and transmitter: Install a new grommet. HINT A new tire pressure warning valve and transmitter is supplied with a grommet. (c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut. Page 7320 (a) Install the lower suspension arm with the camber adjusting cam, No. 2 camber adjusting cam, No. 2 toe adjusting plate, toe adjusting cam, bolt, nut and washer. (b) Align the matchmarks on the No. 2 camber adjusting cam and No. 2 toe adjusting plate. Temporarily install the bolt and nut. 2. CONNECT FRONT LOWER BALL JOINT ATTACHMENT LH (a) Connect the attachment to the steering knuckle with the 2 bolts. Torque : 300 Nm (3059 kgf-cm, 221 ft-lbf) 3. CONNECT FRONT SHOCK ABSORBER WITH COIL SPRING LH (a) Connect the shock absorber with the bolt and nut. 4. INSTALL FRONT STABILIZER LINK ASSEMBLY LH See: Stabilizer Bar/Service and Repair/Installation 5. STABILIZE SUSPENSION See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation 6. TIGHTEN FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH (a) Tighten the bolt and nut. Torque : 280 Nm (2855 kgf-cm, 207 ft-lbf) 7. TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING Page 8874 (a) Disconnect the connectors. (b) Remove the 2 nuts and junction block. (c) Remove the nut and ECU. Page 6344 "Case2" 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 872 Cruise Control Switch: Testing and Inspection CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: INSPECTION 1. INSPECT CRUISE CONTROL MAIN SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the cruise control main switch. Page 6782 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. Component Tests and General Diagnostics Acceleration/Deceleration Sensor: Component Tests and General Diagnostics BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION 1. CHECK YAW RATE SENSOR (a) Check the yaw rate sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 548 Control Module: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 1414 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 8660 Garage Door Opener Transmitter: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 6548 Engine Room R/B, J/B - Engine Compartment Left Page 6533 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 5397 Control Module: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION 1. INSTALL 4WD CONTROL ECU (a) Install the ECU with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. Page 6585 Page 1002 (a) Remove the fuel suction with pump and gauge tube See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Removal and Replacement/Removal. 2. REMOVE FUEL SENDER GAUGE ASSEMBLY (a) Disconnect the fuel sender gauge connector. (b) Press down on the sender gauge claw labeled A. Then slide the sender gauge upward to remove it. Installation 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSTALLATION 1. INSTALL FUEL SENDER GAUGE ASSEMBLY (a) Set the sender gauge to the fuel sub tank. Then slide the sender gauge downward to install it. (b) Connect the fuel sender gauge connector. 2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (a) Install the fuel suction with pump and gauge tube See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Removal and Replacement/Installation. Page 8383 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 6. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 8. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched Page 405 Engine Control Module: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION 1. INSTALL GASKET (a) Clean the ECM seal's surface with non-residue solvent. (b) Attach a new gasket to the ECM. 2. INSTALL ECM (a) Install the ECM with the 4 bolts. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) NOTICE: * Make sure the gasket is not folded or caught on any area on the surrounding part. * Make sure there is no foreign matter caught between the gasket and surrounding part. * Do not damage the gasket. (b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors. NOTICE: * Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do this may cause the lock lever and terminals to break. * Do not twist the wire harness when connecting the ECM connectors. (c) Connect the wire harness clamp. 3. CONNECT CONNECTOR HOLDER BLOCK (a) Connect the connector holder block with the 3 bolts. Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf) Page 3523 NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (CENTER AIRBAG SENSOR) OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR 13. CHECK FOR SHORT TO GND IN CAN BUS WIRE (COMBINATION METER ECU) (a) Disconnect the J28 combination meter ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU (CANH, CANL) OK -- REPLACE COMBINATION METER ASSEMBLY 14. CHECK FOR SHORT TO GND IN CAN BUS WIRE (MAIN BODY ECU) (a) Disconnect the J2 main body ECU connector. Page 2383 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 2603 * Never reuse the O-ring. * When placing a new O-ring on the injector, do not damage it. * Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and intake manifold as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type). (1) for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration. (2) for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector. Locations Tail Lamp Relay: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 724 SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): INSTALLATION 1. INSTALL FRONT POWER SEAT LUMBAR SWITCH LH (a) Install the switch with the 2 screws. 2. INSTALL FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 3. INSTALL RECLINING ADJUSTER RELEASE HANDLE LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 4. INSTALL VERTICAL SEAT ADJUSTER KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 5. INSTALL VERTICAL ADJUSTING HANDLE LH (for 8 Way Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 6. INSTALL FRONT SEAT ASSEMBLY LH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. Page 6024 Torque : 5.8 Nm (59 kgf-cm, 51 in-lbf) 4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY (a) While pushing the 2 brushes toward the inside of the brush holder, insert a pin (diameter: 1.0 mm (0.0394 in.)) into the brush holder hole. (b) Install the generator brush holder with the 2 screws. Torque : 1.8 Nm (18 kgf-cm, 16 in-lbf) (c) Pull out the pin from the generator brush holder. 5. INSTALL GENERATOR REAR END COVER (a) Install the terminal insulator to the generator rectifier end frame. NOTICE: Pay attention to the mounting orientation of the terminal insulator. (b) Install the end cover with the 3 nuts. Transponder Key ECU Alarm Module: Diagrams Transponder Key ECU Page 5768 Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) 15. INSTALL INTERMEDIATE LEVER TENSION SPRING (a) Install the tension spring. 16. INSTALL PARKING BRAKE SHOE LEVER RH HINT Use the same procedures described for the LH side. 17. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY RH HINT Use the same procedures described for the LH side. 18. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY RH HINT Use the same procedures described for the LH side. 19. INSTALL PARKING BRAKE SHOE RETURN SPRING RH HINT Use the same procedures described for the LH side. 20. CHECK PARKING BRAKE INSTALLATION See: Service and Repair/Reassembly 21. INSTALL REAR DISC RH HINT Use the same procedures described for the LH side. 22. ADJUST PARKING BRAKE SHOE CLEARANCE See: Adjustments 23. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY RH HINT Use the same procedures described for the LH side. 24. INSTALL REAR WHEEL RH See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Installation 25. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3220 mm [10 ft. 6.8 in.] Wheelbase Type) (a) Install the No. 1 cable support bracket with the 3 bolts (labeled A). Specifications Axle Nut: Specifications FRONT AXLE HUB NUT LH (for 4WD) Using a 39 mm socket wrench, install the hub nut. Torque.................................................................................................................................................. ...............................338 Nm (3446 kgf-cm, 249 ft-lbf) Page 7516 ^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F. ^ Using the Tire Pressure Chart (Figure 1), find the intersection of the warm tire line at the point corresponding to 54°F and read off the value on the tire pressure change axis. In this case it would be about 6.7 psi. ^ The tires should be filled to: 31.9 + 6.7 psi = 38.6 psi Example 3: Temperature Compensation - "Hot" Tires ^ The vehicle has been driven to the shop on the highway for at least 60 minutes (vehicle has "hot" tires) and tire pressures are set to 31.9 psi. ^ Workshop temperature is 68°F, and the expected lowest ambient temperature in the area is expected to be 14°F. ^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F. ^ Using the tire pressure chart (Figure 1), find the intersection of the hot tire line at the point corresponding to 54°F, and read off the value on the tire pressure change axis. In this case it would be about 9.0 psi. ^ The tires should be filled to: 31.9 + 9.0 psi = 40.9 psi Page 6681 Engine Room R/B, J/B - Engine Compartment Left Locations Backup Lamp Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 4750 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. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 6369 Page 2738 Body Control Module: Diagrams Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 3525 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU WITH ACTUATOR (CANH, CANL) OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal 16. CHECK FOR SHORT TO GND IN CAN BUS WIRE (STEERING ANGLE SENSOR) (a) Disconnect the J6 steering angle sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE SENSOR (CANH, CANL) OK -- REPLACE STEERING ANGLE SENSOR 17. CHECK FOR SHORT TO GND IN CAN BUS WIRE (POWER STEERING ECU) (a) Disconnect the J101 power steering ECU connector. Page 8771 Speaker: Diagrams Front Door Tweeter Page 5850 Acceleration/Deceleration Sensor: Service and Repair Installation BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION 1. INSTALL YAW RATE SENSOR (a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of the sensor bracket. (b) Install the yaw rate sensor with the 2 nuts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * Make sure that the sensor is oriented correctly. * If the sensor is dropped, replace it. * Securely connect the connector. * When installing the sensor, make sure to avoid impacts to the sensor. 2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation 3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning. 6. CHECK YAW RATE SENSOR SIGNAL (a) Check the yaw rate sensor signal See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Locations Central Control Module: Locations NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION m Side Airbag Sensor Impact Sensor: Diagrams Side Airbag Sensor Components Actuator: Service and Repair Components DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): COMPONENTS Page 6319 MJ1-NP1 Page 5213 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 8530 Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Column Shift Type) Components THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): COMPONENTS Removal THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH Page 5654 Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamp, do not twist the wire harness. * Make sure the clamp's rotation stopper touches the installation position. (d) Attach the 3 clips (labeled E). NOTICE: * When installing the clips, do not twist the wire harness. * When installing the clips, securely insert them as shown in the illustration. (e) Connect the speed sensor connector (labeled F). NOTICE: Securely connect the connector. 4. INSTALL FRONT SKID CONTROL SENSOR CLAMP RH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle. 5. INSTALL FRONT SPEED SENSOR RH (a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E). Page 9135 Trailer Towing Part 3 Page 2072 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 1904 (b) Slowly pour coolant into the radiator reservoir until it reaches the FULL line. (c) Install the reservoir cap. (d) Press the inlet and outlet radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant. (e) Install the radiator cap. (f) Start the engine and warm it up until the thermostat opens. HINT The thermostat opening timing can be confirmed by pressing the radiator inlet hose by hand, and checking when the engine coolant starts to flow inside the hose. (g) Maintain the engine speed at 2000 to 2500 rpm. NOTICE: * Make sure that the radiator reservoir still has some coolant in it. * Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature. * If there is not enough coolant, the engine may burn out or overheat. * Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the FULL line. * Run the engine at 2000 rpm until the coolant level has stabilized. (h) Press the inlet and outlet radiator hoses several times by hand to bleed air. CAUTION: * Wear protective gloves. * Be careful as the radiator hoses are hot. * Keep your hands away from the fan. (i) Stop the engine, and wait until the engine coolant cools down to ambient temperature. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (j) Check that the coolant level is between the FULL and LOW lines. If the coolant level is below the LOW line, repeat all of the procedures above. If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines. 4. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement Page 2018 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 6560 Driver Side J/B Inner Circuit Page 1951 Refrigerant: Fluid Type Specifications REFRIGERANT TYPE Refrigerant............................................................................................................................................ ......................................................HFC-134a (R134a) Page 1868 (4) for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector. (5) for Fuel Hose Connector Cover Type: Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration. (6) Check that there is no fuel leakage. 3. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See: Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection. Page 5312 (c) Replace the ATF in the torque converter clutch. (1) If the ATF is discolored and/or has a foul odor, stir the ATF in the torque converter clutch thoroughly and drain the ATF with the torque converter facing upward. (d) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When any marks due to interference are found on the end of a bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and torque converter clutch. (2) Make sure all of the bolts are the same length. (3) Make sure no spring washers are missing. 2. INSPECT DRIVE PLATE (a) Check the drive plate for damage. (b) Set up a dial indicator and measure the runout of the 6 portions around the torque converter clutch contact surfaces. Maximum runout: 0.30 mm (0.0118 in.) (c) If the runout is more than the maximum, or the drive plate is damaged, replace the drive plate See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation. Page 9211 Front Door Panel: Service and Repair Front Door (for Double Cab) Components ENGINE HOOD / DOOR: FRONT DOOR (for Double Cab): COMPONENTS Page 865 Engine Temperature Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm ball joint lock nut wrench, remove the sensor. (c) Remove the gasket from the sensor. Page 2463 Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) (b) Connect the 2 vacuum hoses to the vacuum switching valve. 6. INSTALL STUD BOLT (a) Using an E5 "TORX" socket wrench, install the 2 stud bolts. Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) 7. INSTALL V-BANK COVER PIN (a) Install the pin to the intake manifold. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 8. INSTALL V-BANK COVER BRACKET (a) Install the bracket with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 9. INSTALL FUEL TUBE SUB-ASSEMBLY (a) Install the fuel tube to the intake manifold with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 10. INSTALL INTAKE MANIFOLD Page 849 Yaw Rate Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8912 Parking Assist Control Module: Service and Repair Installation PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: INSTALLATION HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL CLEARANCE WARNING ECU ASSEMBLY (a) Install the clearance warning ECU to the bracket with the 2 nuts. NOTICE: * Avoid any impact to the clearance warning ECU. * Do not drop the ECU. If it is dropped, replace it with a new one. 2. INSTALL CLEARANCE WARNING ECU WITH BRACKET (a) Install the ECU with bracket with the nut and bolt. (b) Connect the ECU connectors and attach the harness clamp. NOTICE: Do not apply excessive force to the wire harnesses. 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation 5. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation. Air Switching Valve (for Bank 1) Air Injection Control Valve: Testing and Inspection Air Switching Valve (for Bank 1) 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): INSPECTION 1. INSPECT AIR SWITCHING VALVE ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the air switching valve. (c) Check the operation of the air switching valve. (1) Check that air does not flow from port A to port B. NOTICE: Make sure the applied pressure is 30 kPa (0.3 kgf/cm2, 4.4 psi) or less. (2) If the result is not as specified, replace the air switching valve. (3) Apply battery voltage across terminals 1 and 2. NOTICE: When applying voltage, do not touch terminals 3, 4 and 5. Page 2093 J/B No.6 Assembly - Instrument Panel Center Page 6756 AB1-DF1 Page 6317 JJ1-JL1 Page 8220 (3) Move SST at least 10 m (32.8 ft.) away from the wheel. NOTICE: Take care not to damage SST wire harness. (d) Activate the seat belt pretensioner. (1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. (2) Check that no one is within 10 m (32.8 ft.) of the wheel. (3) Press SST activation switch to activate the seat belt pretensioner. HINT The seat belt pretensioner operates at the same time SST activation switch's LED illuminates. (e) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: * Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. * Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. (1) Remove the tire (with wheel) and SST. (2) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. Front Seat Outer Belt Assembly (for Double Cab) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): DISPOSAL HINT When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in accordance with the procedures described below. If any abnormality occurs during activation of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Page 8637 2. REMOVE ROOM NO. 1 LIGHT ASSEMBLY (a) Detach the 4 clips and remove the light. 3. REMOVE TELEVISION DISPLAY ASSEMBLY (a) Disconnect the connector. (b) Remove the 4 bolts. (c) Detach the 2 clips and 2 claws, and remove the television display. 4. REMOVE ROOF HEADLINING ASSEMBLY (for CrewMax) (a) Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 5. REMOVE TELEVISION DISPLAY BRACKET Page 4305 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 7053 (b) Inspect the camber, caster and steering axis inclination. Standard camber inclination (unloaded vehicle): for Regular Cab of Standard Deck Standard camber inclination (unloaded vehicle): for Regular Cab of Long Deck Standard camber inclination (unloaded vehicle): for Double Cab of Standard Deck Page 4940 1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Insert the transmission control cable from the vehicle interior, and install the cable retainer with the 2 bolts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) (b) Connect the transmission control cable to the shift lever retainer, and install a new clip. (c) Connect the control cable end to the shift lever. NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that the ridged side of the cable end is facing upward. (d) Move the shift lever to N. (e) Turn the control shaft lever counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position. (f) Connect the control cable with a new clip and the nut. Page 7958 (2) Move SST at least 10 m (32.8 ft.) away from the steering pad tied down to the disc wheel. (e) Cover the steering pad with a cardboard box or tires. (1) Covering method using a cardboard box: Cover the steering pad with the cardboard box and place the weights on the cardboard box in 4 places with at least 190 N (19 kgf, 41.9 lbf). Cardboard box size: Must exceed the following dimensions X 460 mm (1.51 ft.) Y 650 mm (2.13 ft.) NOTICE: * When the dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire which the steering pad is tied to, X should be the following size. X = 460 mm (18.1 in.) + width of tire. * If a cardboard box which is smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. (2) Covering method using tires: Place at least 3 tires without disc wheels on the tire with disc wheel which the steering pad is tied to. Place the tire with disc wheel on them. Page 6425 Power Distribution Relay: Diagrams Specifications Firing Order: Specifications Firing Order 1-8-4-3-6-5-7-2 Page 1422 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 3800 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 6349 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 4002 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 5803 Vacuum Brake Booster: Service and Repair Removal BRAKE: BRAKE BOOSTER: REMOVAL NOTICE: Release the vacuum from the booster by depressing the brake pedal several times. then remove the brake master cylinder sub-assembly from the brake booster assembly. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. 3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (a) Remove the brake master cylinder See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Removal. 4. DISCONNECT VACUUM HOSE ASSEMBLY (a) Slide the clip and disconnect the vacuum hose from the check valve. 5. DISCONNECT BRAKE BOOSTER CONNECTOR (a) Disconnect the 2 brake booster connectors from the brake booster. 6. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 7. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 8. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 10. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 11. REMOVE PUSH ROD PIN (a) Remove the clip and push rod pin. 12. REMOVE BRAKE BOOSTER ASSEMBLY (a) Remove the 4 nuts, and then pull out the brake booster. (b) Remove the brake booster gasket from the brake booster. (c) Loosen the lock nut and then remove the clevis. 13. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY Diagram Information and Instructions Relay Box: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 74 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL 1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE FRONT DOOR SCUFF PLATE RH Page 7287 (b) Using a 32 mm hexagon wrench, remove the rack guide spring cap. (c) Remove the spring and rack guide. 10. REMOVE POWER STEERING CONTROL VALVE (a) Wind vinyl tape around the serrated portion of the control valve. (b) Remove the dust cover from the control valve housing. (c) Remove the 2 bolts. (d) Pull out the control valve from the rack housing. (e) Remove the control valve oil seal. (f) To prevent the oil seal lip from getting damaged, wind vinyl tape around the serrated portion of the control valve. (g) Using a plastic hammer, remove the control valve from the control valve housing. Locations Fuel Pump Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 8102 Page 8911 Parking Assist Control Module: Service and Repair Removal PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE CLEARANCE WARNING ECU WITH BRACKET (a) Disconnect the ECU connectors and detach the harness clamp. NOTICE: Do not apply excessive force to the wire harnesses. (b) Remove the bolt, nut and ECU with bracket. 8. REMOVE CLEARANCE WARNING ECU ASSEMBLY (a) Remove the 2 nuts and clearance warning ECU from the bracket. NOTICE: * Avoid any impact to the clearance warning ECU. * Do not drop the ECU. If it is dropped, replace it with a new one. Page 1196 Applicable Vehicles Components Headlamp Alignment Switch: Service and Repair Components LIGHTING: HEADLIGHT LEVELING SWITCH: COMPONENTS Page 532 Tire Pressure Monitor Receiver / Transponder: Diagrams Page 8240 3. REMOVE CENTER FRONT SEAT ASSEMBLY (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal. 4. REMOVE CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 5. REMOVE CENTER SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 6. DISCONNECT CENTER FRONT SEAT BELT ASSEMBLY RH (a) Remove the bolt and seat belt anchor. 7. REMOVE CENTER SEATBACK ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 8. REMOVE FRONT SEAT HEADREST ASSEMBLY 9. REMOVE FRONT SEAT SHOULDER BELT COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 10. REMOVE UPPER REAR SEATBACK LOCK BEZEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 11. REMOVE LOWER FRONT SEAT SHOULDER BELT COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 12. REMOVE RECLINING REMOTE CONTROL BEZEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 13. REMOVE FRONT SEAT TRAY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 14. REMOVE CENTER FRONT SEAT ARMREST COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 15. REMOVE SEAT FASTENER COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 16. REMOVE FRONT SEATBACK BOARD SUB-ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 17. REMOVE FRONT SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 18. REMOVE CENTER FRONT SEAT BELT ASSEMBLY RH Page 6267 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams 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 9175 Page 7864 (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. 11. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 12. REMOVE BLOWER CASE SUB-ASSEMBLY (a) Remove the 3 screws. (b) Detach the 2 claws and remove the case. 13. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY Page 1476 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 6179 Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Page 3556 (a) Disconnect the DA and DD main body ECU (driver side junction block) connectors. (b) Measure the voltage and resistance according to the value(s) in the table below. * If the result is not as specified, there may be a malfunction on the wire harness side. 2. CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Power Window Control System [w/ Jam Protection Function]) (a) Disconnect the N2 power window regulator master switch assembly connector. (b) Measure the voltage and resistance according to the value(s) in the table below. * If the result is not as specified, there may be a malfunction on the wire harness side. 3. CHECK FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (for Power Window Control System [w/ Jam Protection Function]) Page 2631 8. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Installation 9. INSTALL FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service and Repair/Installation 10. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT (a) Install the water inlet with thermostat See: Cooling System/Thermostat/Service and Repair/Installation. 11. INSTALL FAN SHROUD (a) Install the fan shroud See: Cooling System/Radiator Cooling Fan/Service and Repair/Installation. Page 4767 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 4786 ^ 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 3218 Page 8897 (a) Attach the 8 claws and 2 clips to install the scuff plate. 5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Page 4197 Page 2769 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. 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 8173 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 1415 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Oil Capacity ............................................................................................................................................... ............................................................ 1.2 qt (1.12L) Page 8817 Repair/Front Door (for CrewMax)/Reassembly 8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): COMPONENTS Page 3728 Page 4581 Ignition Switch: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 7704 Wait at least 90 seconds after disconnecting the cable from the negative(-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Regular Cab) 6. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Double Cab, CrewMax) 7. REMOVE FRONT PILLAR GARNISH LH 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 10. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 11. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 12. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 13. REMOVE UPPER REAR CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 14. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 15. REMOVE CONSOLE BOX CARPET 16. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 17. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 18. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 19. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY Page 9006 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. Page 8040 Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable, Driver Side Squib Circuit Page 954 Refrigerant Pressure Sensor / Switch: Service and Repair Removal AIR CONDITIONING: PRESSURE SWITCH: REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Heating and Air Conditioning/Service and Repair 2. REMOVE PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the switch. (c) Remove the O-ring from the pressure switch. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Page 3708 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 1072 Hazard Warning Switch: Diagrams Page 8738 4. Refer to the applicable model and model year in the table for part replacement. 5. Register the new XM Receiver Radio Identification Number (RID). A. Be prepared with the VIN OLD Radio Identification Number (RID) and NEW Radio Identification Number (RID). B. Call the XM Radio Listener line at 1-800-967-2346. C. Provide the necessary information and the representative will complete the request. D. If the customer has an active account confirm XM Satellite Radio service has been refreshed and the radio is active. Once you can listen to channels 4, 11, and 41 you know the activation was successful. Page 5071 Standard backlash: 0.17 to 0.27 mm (0.00670 to 0.01064 in.) (b) If the backlash is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount. HINT * There should be no clearance between the plate washer and differential case. * Make sure that there is ring gear backlash. Washer thickness: 21. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Diagrams Variable Valve Timing Actuator Position Sensor: Diagrams Page 6390 Page 4569 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 7611 Step 6. Pull the filter out of the filter outlet. Cleaning method. Page 1309 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 7587 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Diagram Information and Instructions Headlamp Alignment Control Module: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 1880 (f) Remove the oil filter element and O-ring from the oil filter cap. NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent damage to the cap's O-ring groove. 4. INSTALL OIL FILTER ELEMENT (a) Clean the inside of the oil filter cap, its threads and its O-ring groove. (b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap. (c) Set a new oil filter element to the oil filter cap. (d) Remove any dirt or foreign matter from the installation surface of the engine. (e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap. (f) Using SST, tighten the oil filter cap. SST : 09228-06501 Torque : 25 Nm (255 kgf-cm, 18 ft-lbf) NOTICE: * When tightening the oil filter cap, do not remove the oil filter bracket clip. * Make sure that the oil filter is installed securely as shown in the illustration. * Be careful that the O-ring does not get caught between any surrounding parts. Locations Seat Belt Buckle Switch: Locations SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 8285 3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP 4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY (a) Detach the 2 claws and remove the cover. (b) Remove the bolt and seat belt anchor. (c) Detach the 6 clips and remove the quarter trim panel. 5. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 6. REMOVE REAR SEAT OUTER BELT ASSEMBLY (a) Remove the bolt and shoulder anchor. (b) Remove the bolt and disconnect the seat belt's shoulder anchor. Page 7778 (a) Install the duct with the 2 screws. 11. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY (a) Install the motor with the 3 screws. 12. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the amplifier with the 2 screws. 13. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (a) Install the duct with the screw. 14. INSTALL CLEAN AIR FILTER Page 9352 (c) w/ Rear Fender Mudguard: Install the rear wheel house liner (rear). (1) Install the wheel house liner with 7 new clips. (2) Install the screw. (3) Install the mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and Repair/Installation. (d) Install the rear wheel house liner (center). (1) Install the wheel house liner with 9 new clips. (2) Install the 6 screws. Page 2708 Exhaust Manifold: Service and Repair Installation 1UR-FE EXHAUST: EXHAUST MANIFOLD: INSTALLATION 1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Install a new gasket to the cylinder head and a new gasket to the No. 3 air tube. HINT * Install the exhaust manifold gasket with the gasket tab facing toward the front of the engine. * Install the air tube gasket with the gasket's claws facing the tube. (b) Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration. for nut A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) except nut A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 2. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (a) Install the heat insulator with the 3 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Install a new gasket to the cylinder head and a new gasket to the No. 4 air tube. HINT * Install the exhaust manifold gasket with the gasket tab facing toward the rear of the engine. * Install the air tube gasket with the gasket's claws facing the tube. (b) Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration. Page 5909 Wheel Speed Sensor: Diagrams Front Speed Sensor Page 603 3. INSTALL FRONT BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 4. INSTALL FRONT END PANEL LH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 5. INSTALL FRONT END PANEL RH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 6. INSTALL FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 7. INSTALL FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 8. INSTALL FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 9. INSTALL FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 10. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 11. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. ADJUST FOG LIGHT (a) Adjust the fog light See: Lighting and Horns/Fog/Driving Lamp/Adjustments. Page 9139 Connectors Part 3 Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 8782 Speaker: Testing and Inspection Front Door Speaker (for CrewMax) AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSPECTION 1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 12 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Locations Hood Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 453 Air Bag Control Module: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 3110 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Page 7600 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 2078 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 1213 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS Removal 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL CAUTION: * The procedures should be performed by at least 2 people. * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Disconnect the sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Disconnect the heated oxygen sensor connector and 2 clamps. Page 6635 2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL (a) for AC Power Supply: Disconnect the clamp. (b) Remove the 4 screws and bezel. 5. REMOVE REAR POWER OUTLET SOCKET (for Standard) (a) Detach the claw and remove the power outlet socket. 6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard) (a) Detach the 2 claws and remove the power outlet socket cover. 7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply) (a) Detach the 2 claws and remove the power outlet socket. Page 1607 Four Wheel Drive Selector Switch: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE 4WD CONTROL SWITCH (a) Detach the 3 claws to remove the switch. Page 5053 (b) Using a hammer handle, remove the actuator. 2. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY (a) Remove the 4 bolts. (b) Using a plastic-faced hammer, remove the differential tube. 3. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, tap out the oil seal. SST : 09308-00010 4. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY (a) Using SST, remove the side gear inter shaft. SST : 09350-20015 09369-20040 SST : 09950-40011 09951-04010 Page 4222 Accelerator Pedal: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: INSTALLATION 1. INSTALL ACCELERATOR PEDAL ROD ASSEMBLY NOTICE: * Avoid physical shocks to the accelerator pedal rod assembly. * Do not disassemble the accelerator pedal rod assembly. (a) Install the accelerator pedal rod with the 2 nuts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) (b) Connect the accelerator pedal position sensor connector. Page 4781 ^ 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 115 Electronic Brake Control Module: Diagrams Page 3818 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Page 6058 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. Page 5046 SST : 09504-00011 (f) Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position. (g) Using a dial indicator, adjust the ring gear backlash until it is within the specification. SST : 09504-00011 Standard backlash: 0.10 to 0.20 mm (0.00394 to 0.00788 in.) HINT * The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch. * Perform the measurement at 3 or more positions around the circumference of the ring gear. (h) Tighten the bearing cap bolts. Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf) 14. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Standard total preload (at starting): Page 6487 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 7636 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 6150 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 5772 Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation. 32. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FBE) (a) except Regular Cab Standard Deck: Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation. 33. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1UR-FE) (a) for Regular Cab Standard Deck: Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. 34. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FE) (a) for Regular Cab Standard Deck: Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. 35. INSTALL NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FBE) (a) for Regular Cab Standard Deck: Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. 36. CONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY See: Parking Brake Pedal/Service and Repair/Removal and Replacement/Installation 37. SETTLE PARKING BRAKE SHOE AND DISC See: Service and Repair/Reassembly 38. CHECK PARKING BRAKE PEDAL TRAVEL See: Adjustments 39. ADJUST PARKING BRAKE PEDAL TRAVEL See: Adjustments 40. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 41. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 42. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 44. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 45. INSPECT FOR EXHAUST GAS LEAK (a) If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary. Specifications Wheel Fastener: Specifications FRONT WHEEL For Aluminum Wheel Torque.................................................................................................................................................. .................................131 Nm (1336 kgf-cm, 97 ft-lbf) For Steel Wheel Torque.................................................................................................................................................. ...............................209 Nm (2131 kgf-cm, 154 ft-lbf) REAR WHEEL For Aluminum Wheel Torque.................................................................................................................................................. .................................131 Nm (1336 kgf-cm, 97 ft-lbf) For Steel Wheel Torque.................................................................................................................................................. ...............................209 Nm (2131 kgf-cm, 154 ft-lbf) Page 5615 Steering Angle Sensor: Programming and Relearning BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION PERFORM INITIALIZATION OF STEERING ANGLE SENSOR NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will become misaligned. (a) Check that the steering wheel is in the centered position. (b) Disconnect the negative battery terminal for more than 2 seconds. NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. (c) Reconnect the negative battery terminal. Page 1775 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 1023 Ambient Light Sensor: Service and Repair Removal LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: REMOVAL 1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (a) Disconnect the connector. (b) Remove the 2 claws and sensor. Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Page 2875 Ignition Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY (a) Remove the engine room relay block cover. (b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room relay block. HINT Tape the screwdriver tip before use. (c) Disconnect the 3 connectors. 2. INSPECT INTEGRATION RELAY (IG2) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the IG2 MAIN fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the IG2 MAIN fuse. (b) Measure the resistance of the ignition relay No. 2 (IG2). Page 4082 EGR Cooler: Service and Repair Installation 1UR-FE EMISSION CONTROL: EGR COOLER: INSTALLATION 1. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY (a) Install a new gasket and the No. 2 EGR pipe with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) NOTICE: Make sure the gasket's claws are not caught between the No. 2 EGR pipe and EGR cooler. 2. INSTALL EGR COOLER ASSEMBLY (a) Install the EGR cooler with the 2 bolts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 3. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 4. CONNECT NO. 11 WATER BY-PASS HOSE (a) Connect the No. 11 water by-pass hose. HINT The direction of the hose clamp is indicated in the illustration. 5. CONNECT NO. 8 WATER BY-PASS HOSE Page 6140 Page 7952 CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (f) Install SST. (1) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the front passenger airbag is tied to. (3) Press SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT The airbag is deployed as the LED of SST activation switch comes on. (h) Dispose of the front passenger airbag. CAUTION: Page 6660 4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 5324 Control Module: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 8508 Page 6383 Page 4911 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 11. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 12. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 13. ADJUST SHIFT LEVER POSITION See: Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type) 14. INSPECT SHIFT LEVER POSITION See: Testing and Inspection/Initial Inspection and Diagnostic Overview/SHIFT LEVER ASSEMBLY (for Floor Shift Type) Page 5025 4. INSTALL PROPELLER SHAFT ASSEMBLY (a) Install the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Installation. (b) Install the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Installation. 5. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair 6. INSTALL REAR WHEEL (a) Install the rear wheels. for aluminum wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for steel wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) Components DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): COMPONENTS Diagrams Seat Memory Switch: Diagrams Page 1421 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Page 875 Cruise Control Switch: Service and Repair Removal CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 6. REMOVE CRUISE CONTROL MAIN SWITCH (a) Disconnect the connector. (b) Remove the 2 screws. (c) Remove the switch, as shown in the illustration. Page 6779 Specifications Fuel Pressure: Specifications FUEL PRESSURE Page 4126 Page 7800 Refrigerant Pressure Sensor / Switch: Service and Repair Removal AIR CONDITIONING: PRESSURE SWITCH: REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair 2. REMOVE PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the switch. (c) Remove the O-ring from the pressure switch. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. Page 4163 Page 2134 Tire Pressure Module: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 296 Driver Side J/B - Cowl Side Left Page 8268 for bolt C - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 3. INSTALL REAR SEAT BELT RETRACTOR COVER (a) Attach the 2 claws and 2 clips to install the cover. 4. INSTALL REAR SEAT ASSEMBLY (a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 5. CONNECT CENTER REAR SEAT OUTER BELT ASSEMBLY (a) Connect the rear seat center seat outer belt with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body. Components SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for CrewMax): COMPONENTS Page 6143 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. Page 6926 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 7658 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 7653 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 6846 Page 2432 Refer to the Technical Information System (TIS) when replacing the oil filter applicable model and model year Repair Manual: Page 8332 Impact Sensor: Diagrams Front Airbag Sensor Page 1028 Brake Light Switch: Diagrams Page 8710 Page 4215 Page 1706 Standard wheel angle (unloaded vehicle): for Double Cab of Long Deck Page 7974 2. INSTALL ROOF HEADLINING ASSEMBLY (a) Refer to the procedures from "INSTALL ROOF HEADLINING ASSEMBLY" (for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: COMPONENTS Page 8554 Collision Avoidance Module: Diagrams Page 364 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 3041 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 7954 CAUTION: * Do not connect SST connector (yellow colored) to the airbag. * If the LED comes on when the activation switch is not being pressed, SST malfunction is possible, so replace SST with a new one. (3) Disconnect SST from the battery. (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the lower steering column cover. (1) While turning the steering wheel assembly to the right and left, remove the 2 screws and steering column cover lower. (e) Install SST. CAUTION: Check that there is no looseness in the steering wheel assembly and steering pad. (1) Disconnect the airbag connector (yellow colored) from the spiral cable with steering sensor. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect SST connector to the airbag connector of the spiral cable with steering sensor. SST : 09082-00700 SST : 09082-00780 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Page 3045 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. A760F Automatic Transmission System Transfer Case Actuator: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 8221 * Never dispose of a front seat outer belt that has a non-activated pretensioner. * The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to nearby people. * When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (32.8 ft.) away from the front seat outer belt. * Use gloves and safety glasses when handling a front seat outer belt with an activated pretensioner. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. * Perform procedures in a place away from electrical interference. * When activating the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). 1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery to activate the seat belt pretensioner. (a) Check if SST is functioning properly. SST : 09082-00700 CAUTION: When activating the seat belt pretensioner, always use the specified SST. (1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. HINT Do not connect the yellow connector. The yellow connector is used to connect to the seat belt pretensioner. Engine Controls - ECM Update For Shift Performance Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 9171 Refer to the service kit instruction sheet for further detail. Page 9363 3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount. These will be reused when installing the new No.3 cab mount bolts. 4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse. 5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount bolts. Page 4870 Transmission Speed Sensor: Diagrams Page 6118 5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY (a) Fit the clamp of the brush holder into the starter commutator end frame. (b) Install the commutator end frame with the 2 screws. Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf) 6. INSTALL STARTER ARMATURE PLATE (a) Install the starter armature plate to the starter yoke. NOTICE: Install the starter plate so that the keyway is positioned between key-A and key-B. 7. INSTALL STARTER YOKE ASSEMBLY (a) Align the key of the starter yoke with the keyway located on the starter drive housing. (b) Using a T25 "TORX" socket wrench, install the 2 bolts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) 8. INSTALL MAGNET STARTER SWITCH ASSEMBLY (a) Apply high temperature grease to the plunger hook. Page 4576 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 3797 Crankshaft Position Sensor: Diagrams Page 1679 for Double Cab of Long Deck for CrewMax of standard deck Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Capacity Front (4WD models) Capacity ............................................................................................................. .............................................................................................. 2.2 qt (2.05L) Rear Regular Cab Models Standard Bed ............................................................................................ ......................................................................................................... 4.3 qt (4.05L) Long Bed ............. .............................................................................................................................................................. ................................ 4.9 qt (4.60L) Double Cab and Crew Max Models Capacity ...................................................................................... .................................................................................................................... 4.9 qt (4.60L) Page 114 Electronic Brake Control Module: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 4917 (c) Securely connect the 2 wire terminals to terminal 6 and 13 of the transmission control switch connector. 3. CONNECT NO. 1 SHIFT LOCK PLATE SUB-ASSEMBLY (a) Using a hammer, tap in the spring pin to connect the shift lock plate and shift lock solenoid. 4. INSTALL SHIFT LOCK SOLENOID (a) Install the shift lock solenoid with No. 1 shift lock plate sub-assembly, 2 bushes and collar to the column shift control shift lever retainer with the screw. Torque : 1.2 Nm (12 kgf-cm, 11 in-lbf) (b) Attach the 2 claws to install the shift lock solenoid bracket. (c) Securely connect the 2 wire terminals to terminal 1 and 8 of the transmission control switch connector. Components Front Fender Liner: Service and Repair Components EXTERIOR: FENDER LINER (for Front Side): COMPONENTS Page 1319 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 6065 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 2274 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Page 3085 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Power Window Control System (w/ Jam Protection Function) Power Window Relay: Locations Power Window Control System (w/ Jam Protection Function) WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/ Jam Protection Function): PARTS LOCATION Page 4965 Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch Page 7705 (a) Detach the 4 clips. (b) Disconnect the connector and remove the panel. 20. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift Type)/Removal 21. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift Type)/Removal 22. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System without USB Audio System) See: Accessories and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor Shift Type)/Removal 23. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System with USB Audio System) See: Accessories and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor Shift Type)/Removal Installation AIR CONDITIONING: AIR CONDITIONING PANEL (for Floor Shift Type): INSTALLATION 1. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System without USB Audio System) See: Accessories and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor Shift Type)/Installation 2. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System with USB Audio System) See: Accessories and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor Shift Type)/Installation 3. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift Type)/Installation 4. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift Type)/Installation 5. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY Diagrams Shift Interlock Solenoid: Diagrams Page 5256 2. Inspect the front driveshaft (propeller shaft assembly) for a loose parts label that may be contacting other components (see Figure 1). Is the label on the front driveshaft (propeller shaft assembly) loose and contacting other components? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the cause of this condition. 3. Completely remove the front driveshaft parts label. 4. Test drive and confirm there is no abnormal noise present when in 4WD. Page 6050 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 8470 Alarm System Transmitter: Service and Repair Installation ENGINE IMMOBILISER: TRANSPONDER KEY ECU: INSTALLATION 1. INSTALL TRANSPONDER KEY ECU (a) Hook the upper part of the ECU and the lower part in that order to install the ECU. 2. INSTALL TRANSPONDER KEY BRACKET (w/ Bracket) (a) Install the transponder key bracket with the 2 screws. 3. INSTALL AIR CONDITIONING UNIT (a) Install the air conditioning unit See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Installation. 4. REGISTER ECU - ECM COMMUNICATION ID (a) Register the ECU - ECM communication ID See: Testing and Inspection/Programming and Relearning/Engine Immobiliser System. Page 7020 for Double Cab of Long Deck for CrewMax of standard deck Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Bypass Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 3734 HINT The wavelength becomes shorter as engine rpm increases. (i) WAVEFORM 8: HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10 minutes or more. (j) WAVEFORM 9: Page 3505 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU) OK -- Continue to next step. 9. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A46 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Drivetrain - Rear Differential Growl/Whine While Driving Differential Case: Customer Interest Drivetrain - Rear Differential Growl/Whine While Driving T-SB-0297-10 November 2, 2010 Rear Differential Housing Oil Baffle Growl/Whine Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some vehicles may exhibit a growl or whine noise from the rear when the vehicle is in motion. Production changes have been made to prevent this noise. Follow the procedure in the bulletin to address this noise condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 4364 4. INSTALL V-BANK COVER See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. CHECK FOR FUEL LEAK See: Fuel Injector/Service and Repair/Installation Components Steering Angle Sensor: Service and Repair Components BRAKE CONTROL: STEERING ANGLE SENSOR: COMPONENTS Page 5464 Transfer Case Actuator: Diagrams Page 6113 (a) Remove the exhaust manifold RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal. 2. REMOVE STARTER COVER (a) Remove the 3 bolts and starter cover. 3. REMOVE STARTER ASSEMBLY (a) Disconnect the 2 wire harness clamps. (b) Disconnect the starter connector. (c) Remove the nut and disconnect the starter wire. (d) Remove the 2 bolts and starter. Page 8975 Shock Sensor: Diagrams Page 6564 J/B No.6 Assembly Inner Circuit Page 2313 (a) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to fix it in place. (b) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTICE: * Be careful not to damage the cylinder head with the wrench. * Do not disassemble the camshaft timing gear. (c) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTICE: Be careful not to damage the cylinder head with the wrench. (d) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH. (e) Remove the No. 1 and No. 2 chains from the gears. 11. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (a) Remove the 2 bolts and chain tensioner. 12. REMOVE CAMSHAFT BEARING CAP RH (a) Make sure that the knock pin of the camshaft is positioned as shown in the illustration. Page 827 Wheel Speed Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 3429 (a) Reconnect the J86 No. 1 junction connector connector. NEXT -- Continue to next step. 4. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR) (a) Disconnect the J113 No. 2 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) OK -- Continue to next step. 5. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) (a) Disconnect the J94 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step. 6. CONNECT CONNECTOR (a) Reconnect the J94 No. 1 junction connector connector. (b) Reconnect the J113 No. 2 junction connector connector. Page 1515 Neutral Safety Switch: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL 1. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut and disconnect the cable. 2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Disconnect the switch connector. (b) Remove the nut, spring washer and transmission control shaft lever RH. (c) Using a screwdriver, bend the tabs of the lock washer. (d) Remove the lock nut and lock washer. (e) Remove the bolt and switch. Page 2973 with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 5. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (b) Connect the air fuel ratio sensor connector. (c) Connect the heated oxygen sensor connector and 2 clamps. 6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Page 7322 Control Arm: Overhaul Disassembly SUSPENSION: FRONT LOWER SUSPENSION ARM: DISASSEMBLY 1. REMOVE FRONT NO. 1 LOWER ARM BUSH LH (a) Using a chisel and hammer, pry the flange of the bush outward. (b) Using SST, remove the bush. SST : 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04011 09957-04010 09958-04011 SST : 09950-60010 09951-00540 2. REMOVE FRONT NO. 2 LOWER ARM BUSH LH Page 1994 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 7299 Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: Use the formula calculate special torque values for situations for situations where a union nut wrench is combined with a torque wrench See: Service Precautions Drivetrian - Rear End Howling/Growling Noises Axle Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Front Power Seat Lumbar Switch (for Manual Seat) Power Seat Switch: Testing and Inspection Front Power Seat Lumbar Switch (for Manual Seat) SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): INSPECTION 1. INSPECT FRONT POWER SEAT LUMBAR SWITCH LH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Locations Impact Sensor: Locations SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 8139 Seat Occupant Sensor: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 4313 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. Components Steering Angle Sensor: Service and Repair Components BRAKE CONTROL: STEERING ANGLE SENSOR: COMPONENTS Page 1705 Standard wheel angle (unloaded vehicle): for Double Cab of Standard Deck Page 2043 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 797 Parking Brake Warning Switch: Service and Repair Reassembly PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY 1. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the switch with the screw. Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf) Page 7515 Tire Pressure Adjustment Recommended Tire Pressure Adjustment: NOTE Use a high quality accurate tire pressure gauge, and check its accuracy regularly. ^ Consider the difference of the air temperature in the workshop and the lowest ambient temperature that may be expected in the next few weeks (especially in winter). ^ Use the chart (Figure 1) to compensate for temperature of the tires when adjusting tire pressure. Use temperature compensation Example 1 for the spare tire. Example 1: Temperature Compensation - "Cold" Tires ^ The vehicle has been parked overnight outside shop (vehicle has "cold" tires) and tire pressures are set to 31.9 psi. ^ Workshop temperature is 68°F and expected lowest ambient temperature in the local area is to be 14°F. ^ Subtract the expected lowest temperature (14 F) from the workshop temperature (68°F) = 54°F. ^ Using the tire pressure chart (Figure 1) find the intersection of the cold tire line at the point corresponding to 54°F and read oft the value on the tire pressure change axis. In this case it would be about 4.9 psi. ^ The tires should be filled to: 31.9 + 4.9 psi = 36.8 psi Example 2: Temperature Compensation - "Warm" Tires ^ The vehicle has been driven to the shop on surface streets for about 30 minutes (vehicle has "warm" tires) and tire pressures are set to 31.9 psi. ^ Workshop temperature is 68 F and expected lowest ambient temperature in your area is to be 14°F. Air Fuel Ratio Sensor Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS Page 3848 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. (c) for 2WD: Connect the air fuel ratio sensor connector. 2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Connect the front No. 2 exhaust pipe to the exhaust pipe support. (b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (c) Connect the air fuel ratio sensor connector. (d) Connect the heated oxygen sensor connector. 3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) Page 6689 Page 6887 Power Distribution Module: Service and Repair Installation OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION 1. INSTALL VOLTAGE INVERTER ASSEMBLY (a) Connect the voltage inverter connector. (b) Install the voltage inverter with the 2 bolts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 4793 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 8689 Integrated Accessory Switch Assembly: Diagrams Page 181 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Locations Actuator: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 4995 6. REMOVE SHIFT SOLENOID VALVE S1 (a) Remove the bolt, valve body wire harness clamp and shift solenoid valve. 7. REMOVE SHIFT SOLENOID VALVE S4 (a) Remove the bolt and shift solenoid valve. 8. REMOVE SHIFT SOLENOID VALVE S2 9. REMOVE SHIFT SOLENOID VALVE S3 (a) Remove the bolt and shift solenoid valve. Reassembly A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REASSEMBLY Page 9079 Trailer Lamps: Electrical Diagrams Trailer Towing Part 1 Page 3985 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 969 Dimmer Switch: Testing and Inspection METER: LIGHT CONTROL RHEOSTAT: INSPECTION 1. INSPECT LIGHT CONTROL RHEOSTAT (w/o TAIL Cancel Switch) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the rheostat. 2. INSPECT LIGHT CONTROL RHEOSTAT (w/ TAIL Cancel Switch) (a) Measure the resistance according to the value(s) in the table below. Diagrams Shift Interlock Solenoid: Diagrams Page 7030 for Double Cab of Long Deck Page 4939 (a) Move the shift lever to N. (b) Disconnect the transmission control cable end from the shift lever. (c) Remove the clip and disconnect the transmission control cable from the shift lever retainer. (d) Remove the nut and clip, and disconnect the transmission control cable from the automatic transmission. (e) Remove the nut and disconnect the transmission control cable support. (f) Remove the 2 bolts and then pull the transmission control cable into the vehicle to remove it. Installation A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Floor Shift Type): INSTALLATION Page 3323 Page 5760 17. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 4180 mm [13 ft. 8.6 in.] Wheelbase Type) (a) Remove the adjustment nut and lock nut (labeled A). (b) Remove the bolt (labeled B) and cable retainer. (c) Remove the 3 nuts (labeled C) and 3 clamps from the body. (d) Disconnect the 3 clamps (labeled D) from the No. 1 parking brake cable. (e) Remove the 2 bolts (labeled E) and No. 1 parking brake cable from the inside of the vehicle. NOTICE: Do not bend and twist the parking brake cable. (f) Remove the 3 bolts (labeled F) and No. 1 cable support bracket. 18. REMOVE REAR WHEEL LH 19. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Service and Repair/Disassembly 20. REMOVE REAR DISC LH See: Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Removal 21. REMOVE PARKING BRAKE SHOE RETURN SPRING LH See: Service and Repair/Disassembly 22. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Service and Repair/Disassembly 23. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Service and Repair/Disassembly 24. REMOVE PARKING BRAKE SHOE LEVER LH See: Service and Repair/Disassembly 25. REMOVE INTERMEDIATE LEVER TENSION SPRING (a) Remove the tension spring. Page 1637 * If the result is not as specified, replace the power window regulator switch. Page 6694 Page 7508 Tire Pressure Warning Reset Switch: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING RESET SWITCH (a) Disconnect the switch connector. (b) Detach the 2 claws and remove the reset switch. Locations Fuse: Locations Engine Room R/B, J/B - Engine Compartment Left Page 6686 Fuse: Application and ID Fuse Layout and Amperage Ratings Fuse Block Location - Engine Compartment Fuse Location - Engine Compartment Locations Steering Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 1350 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Page 8905 6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 6853 Page 7698 Removal AIR CONDITIONING: AIR CONDITIONING PANEL (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative(-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. 3. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Double Cab: Page 6646 (a) Attach the claw to install the power outlet socket. 6. INSTALL CONSOLE BOX BEZEL (a) Attach the 5 claws to install the console box bezel. (b) Connect the connector. 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Components OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Page 549 Control Module: Diagrams Page 6839 Page 7003 Engine Room R/B And Engine Room J/B Inner Circuit Page 3568 Page 1481 Push the terminal retainer down to the temporary lock position. Page 8242 12. INSTALL CENTER SEATBACK ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 13. CONNECT CENTER FRONT SEAT BELT ASSEMBLY RH (a) Install the belt anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 14. INSTALL CENTER SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 15. INSTALL CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 16. INSTALL CENTER FRONT SEAT ASSEMBLY (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation. 17. INSTALL FRONT SEAT ASSEMBLY (for Power Seat) (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 18. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat) (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. Components SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): COMPONENTS Page 3737 (q) WAVEFORM 16: HINT The wavelength changes when the air injection control driver detects malfunctions in the air injection system See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0412 (r) WAVEFORM 17: HINT The wavelength becomes shorter as engine rpm increases. (s) WAVEFORM 18: Page 9251 Locations Collision Avoidance System Switch: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 8966 Remote Switch: Locations Navigation System (w/ USB Audio System) NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION Page 6793 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 702 Power Seat Switch: Locations Power Mirror Control System (w/ Memory) MIRROR: POWER MIRROR CONTROL SYSTEM (w/ Memory): PARTS LOCATION Page 3742 (b) Spray gasket remover or equivalent on the remaining tape of the gasket. NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth. (c) Remove the tape of the gasket without using bladed objects. Page 7728 Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 1638 Power Window Switch: Testing and Inspection Power Window Master Switch WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: ON-VEHICLE INSPECTION 1. CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/o Jam Protection Function) (a) for Regular Cab: (1) Remove the master switch See: Service and Repair/Power Window Master Switch/Removal. (2) Reconnect the switch connector. (3) Measure the voltage according to the value(s) in the table below. Standard voltage: (b) for Double Cab: (1) Remove the power window regulator master switch See: Service and Repair/Power Window Master Switch/Removal. (2) Reconnect the switch connector. (3) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 9083 Connectors Part 1 Page 3358 Symbols Used Within Diagrams Symbols Used Within Diagrams Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 7362 Removal SUSPENSION: FRONT SHOCK ABSORBER: REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING LH Testing and Inspection Steering Gear: Testing and Inspection POWER STEERING: STEERING GEAR: INSPECTION 1. INSPECT TIE ROD END SUB-ASSEMBLY LH (a) Secure the tie rod end LH in a vise. (b) Install the nut to the stud bolt. (c) Flip the ball joint back and forth 5 times or more. (d) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the fifth turn. Standard turning torque: 1.0 to 3.9 N*m (10 to 40 kgf*cm, 9 to 34 in.*lbf) (e) If turning torque is not within the specified range, replace the tie rod end LH. 2. INSPECT TIE ROD END SUB-ASSEMBLY RH HINT Use the same procedures described for the LH side. Power Steering Oil Pressure Sensor Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor Page 3595 Manifold Pressure/Vacuum Sensor: Diagrams Page 5975 Ignition Switch: Testing and Inspection 1UR-FE STARTING: IGNITION SWITCH: INSPECTION 1. INSPECT IGNITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the ignition switch assembly. Page 6807 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 6733 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 4017 (a) Install a new gasket and the air switching valve with the 3 bolts. Torque : 24 Nm (245 kgf-cm, 18 ft-lbf) NOTICE: Make sure the gasket's claws are not caught between the air switching valve and No. 3 air tube. (b) Install the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (c) Connect the wire harness clamp bracket with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (d) Connect the clamp and connector. 2. CONNECT NO. 1 AIR HOSE (a) Align the paint mark with the projection and connect the No. 1 air hose. HINT Make sure the direction of the hose clamp is as shown in the illustration. 3. CONNECT NO. 3 VENTILATION HOSE (a) Connect the No. 3 ventilation hose. HINT The direction of the hose clamp is indicated in the illustration. Page 3388 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Engine Controls - ECM Update For Shift Performance Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 3446 OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR 13. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU) (a) Disconnect the J28 combination meter ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU (CANH, CANL) OK -- REPLACE COMBINATION METER ASSEMBLY 14. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU) (a) Disconnect the J2 main body ECU connector. Page 766 Acceleration/Deceleration Sensor: Programming and Relearning BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION 1. DESCRIPTION * After replacing components relating to the VSC or performing "Front wheel alignment adjustment", clear and read the sensor calibration data. * Follow the chart to perform calibration. 2. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING TECHSTREAM) (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. (c) Operate the Techstream to erase the codes (select Reset Memory). HINT Refer to the Techstream operator's manual for further details. 3. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND DECELERATION SENSOR (WHEN USING TECHSTREAM) NOTICE: * While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it stationary. (Do not start the engine.) * While obtaining the zero point, do not depress the brake and accelerator pedal. * Obtain the zero point on a level surface (with an inclination of 1° or less). (a) Enter Test Mode. (1) Turn the ignition switch off. (2) Check that the shift lever is in parking or neutral and apply the parking brake. CAUTION: Application of the parking brake is not necessary for entering test mode. However, apply the parking brake for safety. (3) Connect the Techstream to the DLC3. (4) Turn the ignition switch to ON. NOTICE: Do not start the engine. (5) Set the Techstream to test mode (select Test Mode). HINT Refer to the Techstream operator's manual for further details. (b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor. (1) Keep the vehicle stationary on a level surface for 1 second or more. HINT Diagrams EGR Valve: Diagrams ACC Cut Relay Power Distribution Relay: Testing and Inspection ACC Cut Relay 1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION 1. REMOVE ACC CUT RELAY (a) Remove the clip. (b) Detach the 2 clips and remove the cowl side trim board RH. (c) Remove the relay. 2. INSPECT ACC CUT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL ACC CUT RELAY (a) Install the relay. (b) Attach the 2 clips to install the cowl side trim board RH. (c) Install the clip. Page 305 Driver Side J/B Inner Circuit Page 309 J/B No.6 Assembly Inner Circuit Page 497 6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU (a) Disconnect the 2 ECU connectors. (b) Remove the 2 screws and ECU. Page 2438 Oil Pressure Sender: Testing and Inspection 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Disconnect the sender gauge connector. (b) Apply battery positive (+) voltage to the sender gauge terminal through a test LED. (c) Check that the LED does not illuminate when the engine is stopped. (d) Check that the LED flashes when the engine is running. The number of flashes varies with engine speed. If the operation is not as specified, replace the oil pressure sender gauge assembly. Page 8950 Removal PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 3. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal Page 1399 Impact Sensor: Service and Repair Side Airbag Sensor (for Double Cab) Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): COMPONENTS Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Components Evaporator Temperature Sensor / Switch: Service and Repair Components AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: COMPONENTS Page 3416 Information Bus: Symptom Related Diagnostic Procedures Problem Symptoms Table MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS TABLE HINT * Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. * Inspect the fuses and relays related to the system before inspecting the suspected areas below. Integration Control and Panel Assembly Communication Error MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: Integration Control and Panel Assembly Communication Error - Integration Control and Panel Assembly Communication Error DESCRIPTION The LIN communication of the components related to the mirror heater occurs between the air conditioning amplifier assembly (A/C ECU) and integration control and panel assembly. WIRING DIAGRAM INSPECTION PROCEDURE NOTICE: When using the Techstream with the ignition switch OFF to troubleshoot: Connect the Techstream to the vehicle, and turn a courtesy switch on and off at 1.5 second intervals until communication between the tester and vehicle begins. PROCEDURE 1. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - INTEGRATION CONTROL AND PANEL) Page 1683 for CrewMax of standard deck Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 3065 Page 9016 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Components Ignition Coil: Service and Repair Components 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS Page 8186 Seat Occupant Classification Module - Air Bag: Testing and Inspection SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: ON-VEHICLE INSPECTION 1. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the ECU. CAUTION: * For removal and installation procedures of the occupant classification ECU, be sure to follow the correct procedure. * If the airbags have deployed, replace the occupant classification ECU on the side in which the collision occurred. Replace both if necessary. Page 643 11. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 4135 Page 7279 Removal POWER STEERING: STEERING GEAR: REMOVAL 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE FRONT WHEELS 3. REMOVE ENGINE ASSEMBLY (a) for 1GR-FE: Page 9039 Connectors Part 2 Page 7919 Air Bag: Testing and Inspection Front Passenger Side Knee Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY: ON-VEHICLE INSPECTION 1. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the lower No. 2 instrument panel airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the lower No. 2 instrument panel airbag with a new one: Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag. 2. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the lower No. 2 instrument panel airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the lower No. 2 instrument panel airbag with a new one: * Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag. * Cracks or other damage to the connector. * Deformation or cracks on the instrument panel reinforcement. CAUTION: For removal and installation procedures of the lower No. 2 instrument panel airbag, be sure to follow the correct procedure. Page 1265 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Page 1847 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 3526 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU (CANH, CANL) OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal 18. CHECK FOR SHORT TO GND IN CAN BUS WIRE (CENTER AIRBAG SENSOR) (a) Disconnect the J46 center airbag sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. Page 7390 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 7057 Standard caster inclination (unloaded vehicle): for Regular Cab of Long Deck Standard caster inclination (unloaded vehicle): for Double Cab of Standard Deck Page 7051 Standard wheel angle (unloaded vehicle): for CrewMax of standard deck Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 2329 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 4183 Page 4812 Actuator: Service and Repair Installation DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): INSTALLATION 1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator. (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the differential tube as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent HINT Install the actuator within 10 minutes of applying seal packing. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the actuator onto the differential tube. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (g) Install the 4 bolts. Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) (h) Connect the actuator hose. (i) Connect the actuator connector. 2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and Inspection/Component Tests and General Diagnostics/Touch Select 2-4 and High-Low System. Page 7500 Tire Pressure Sensor: Service and Repair Disposal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire pressure warning valve and transmitter, remove the battery and dispose of it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Use the tip of a screwdriver to pry off the back cover. (b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that connect the battery to the base board. Page 3196 Camshaft Position Sensor: Diagrams Page 9282 Hood Sensor/Switch (For Alarm): Diagrams Page 6745 Fuse Block: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Page 3080 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 421 Fuel Pump Control Unit: Locations Double Cab Body Page 4697 Transmission Speed Sensor: Testing and Inspection A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION 1. INSPECT SPEED SENSOR NT (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. 2. INSPECT SPEED SENSOR SP2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. Page 3542 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE COMBINATION METER ASSEMBLY ECM Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: ECM Communication Stop Mode ECM Communication Stop Mode DESCRIPTION WIRING DIAGRAM Page 4400 Parts Information NOTE The fuel sending unit lower cover is installed and supplied as part of the fuel tank assembly part numbers listed in the part information table above. Warranty Information Installation Procedure 1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover (2 places). 2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1 place). Locations Electronic Throttle Actuator: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6175 Connectors Part 1 Connectors Part 2 Locations Hazard Flasher Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 7721 Control Module HVAC: Service and Repair Installation AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: INSTALLATION 1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the amplifier with the 2 screws. (b) for Manual Air Conditioning System: Connect the 2 connectors. (c) for Automatic Air Conditioning System: Connect the 3 connectors. 2. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (a) Install the duct with the screw. 3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY for Column Shift Type: Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. for Floor Shift Type: Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL LOWER INSTRUMENT PANEL for Column Shift Type: Page 7957 CAUTION: * Tightly wind the wire harnesses around the bolts so that there is no slack. * Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the steering pad may become loose due to the shock when the airbag is deployed. (4) Face the airbag deployment side of the steering pad upward. Separately tie the left and right sides of the steering pad to the disc wheel through the hub nut holes. Position SST connector so that it hangs downward through the hub hole of the disc wheel. CAUTION: * Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the steering pad may become loose due to the shock when the airbag is deployed. * Always tie down the steering pad with the airbag deployment side facing upward. NOTICE: As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. (d) Install SST. CAUTION: Place the disc wheel on level ground. (1) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the disc wheel. Page 8303 When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor) make sure the retractor is locked when in use. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat belt are both facing outward as shown in Figure 4. You will hear a click when the tab locks into the buckle. When not in use, remove the extender and store in the vehicle for future use. On vehicles equipped with SRS - Occupant Classification System (OCS)*, the extender tab should be buckled into the buckle AFTER the occupant sits down in the seat. Leaving extender installed in the buckle before sitting down will cause the OCS to be in the "airbag off" or disarmed state. *OCS will enable or disable the passenger front and side airbags based on passenger weight and seat belt latch position classifying the passenger as a child or adult. When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the possibility of personal injury. ^ NEVER use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. Page 9111 "Case2" 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 4252 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 596 Parking Assist Distance Sensor: Diagrams Page 2947 Manifold Pressure/Vacuum Sensor: Diagrams Page 6727 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 6184 2. REMOVE CONSOLE BOX BEZEL (a) Disconnect the connector. (b) Using a screwdriver, detach the 5 claws and remove the console box bezel. HINT Tape the screwdriver tip before use. 3. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 4. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. Page 8902 Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS Page 575 Page 1504 Ignition Switch: Service and Repair Removal 1UR-FE STARTING: IGNITION SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal. (b) for Manual Tilt and Manual Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal. (c) for Power Tilt and Power Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal. 3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Disassembly 4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly 5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly 6. REMOVE IGNITION SWITCH ASSEMBLY (a) Detach the 2 claws and remove the ignition switch from the steering lock. Page 7665 (a) Remove the 6 clips and seal. 3. REMOVE FAN AND GENERATOR V BELT See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 4. DISCONNECT DISCHARGE HOSE (a) Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler compressor. (b) Remove the O-ring from the cooler refrigerant discharge hose. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. 5. DISCONNECT SUCTION HOSE (a) Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor. (b) Remove the O-ring from the cooler refrigerant suction hose. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. 6. REMOVE COOLER COMPRESSOR ASSEMBLY (a) Disconnect the connector. Page 6054 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 2975 (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. Page 8245 (c) Detach the 7 clips and 2 claws, and remove the pillar garnish. 7. REMOVE CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 8. REMOVE FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the nut and shoulder anchor. (b) Disconnect the pretensioner connector as shown in the illustration. (c) Remove the 2 bolts and seat belt. Installation SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT SEAT OUTER BELT ASSEMBLY Page 3552 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE STEERING ANGLE SENSOR BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (STEERING ANGLE SENSOR - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE STEERING ANGLE SENSOR 4WD Control ECU Communication Stop Mode Page 9048 Page 6546 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Components Variable Valve Timing Actuator: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS Page 1063 Door Switch: Service and Repair Rear Door Courtesy Switch Components LIGHTING: REAR DOOR COURTESY SWITCH: COMPONENTS Page 8717 Amplifier: Service and Repair Removal AUDIO / VISUAL: STEREO COMPONENT AMPLIFIER: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT SEAT ASSEMBLY RH (a) for Manual Seat: Remove the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. (b) for Power Seat: Remove the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 3. REMOVE AUDIO AMPLIFIER COVER (a) Detach the 3 clips and remove the cover. 4. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY (a) Disconnect the 3 connectors. (b) Remove the 3 bolts and amplifier. Page 188 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 8083 Impact Sensor: Service and Repair Side Airbag Sensor (for Double Cab) Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): COMPONENTS Page 3605 Applicable Vehicles Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 2796 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 5147 (b) Coat the threads of a new nut with hypoid gear oil. (c) Using SST to hold the companion flange, tighten the nut. SST : 09330-00021 09330-00030 Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less) 14. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload. Standard preload (at starting): (b) If the result is not as specified, adjust the preload. 15. STAKE REAR DRIVE PINION NUT (a) Using a chisel and hammer, stake the nut. 16. INSTALL PROPELLER SHAFT ASSEMBLY (a) Install the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Installation. (b) Install the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft Assembly/Installation. 17. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair Page 8793 (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Rear Door Speaker (for Double Cab) AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): INSPECTION 1. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for Standard) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for 10 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Page 8244 After the ignition switch is turned LOCK, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch LOCK, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. 2. REMOVE FRONT SEAT ASSEMBLY (a) for Manual Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. (b) for Power Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 3. REMOVE FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Partially remove the front door opening trim weatherstrip so that the center lower pillar garnish and center pillar garnish can be removed. 6. REMOVE LOWER CENTER PILLAR GARNISH (a) Detach the 2 claws and remove the cover. (b) Remove the bolt and seat belt anchor. Page 8048 Page 2140 (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 6103 (2) Using a dial gauge, measure the circle runout. Standard runout: 0.02 mm (0.000787 in.) Maximum runout: 0.05 mm (0.00197 in.) (3) If the circle runout is more than the maximum, replace the starter armature assembly. (d) Using a vernier caliper, measure the commutator diameter. Standard diameter: 29.0 mm (1.14 in.) Minimum diameter: 28.0 mm (1.10 in.) (e) If the diameter is less than the minimum, replace the starter armature assembly. (f) Check that the undercut portion is clean and free of foreign matter. Smooth out the edge. Standard undercut depth: 0.7 mm (0.0276 in.) Minimum undercut depth: 0.2 mm (0.00787 in.) (g) If the undercut depth is less than the minimum, increase the depth using a hacksaw blade. 4. INSPECT STARTER BRUSH HOLDER ASSEMBLY (a) Using a vernier caliper, measure the brush length. Standard length: 14.4 mm (0.567 in.) Page 3531 C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal Open In CAN Main Wire CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Open in CAN Main Wire - Open in CAN Main Wire DESCRIPTION There may be an open circuit in the CAN main wire and/or the DLC3 branch wire when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is 69 Ohms or higher. WIRING DIAGRAM INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. Page 9159 Refer to the service kit instruction sheet for further detail. Page 6361 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 6562 Driver Side J/B Inner Circuit Page 6388 Page 8945 Page 8339 (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If the front airbag sensor has defects as mentioned below, replace it with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. 3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: * For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the front airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for Double Cab) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis Page 1491 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 2637 Coolant: Fluid Type Specifications Coolant Type Use either of the following: "Toyota Super Long Life Coolant" Similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. Do not use plain water alone. Page 1274 Throttle Position Sensor: Diagrams Page 9017 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 6712 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 7744 15. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY (a) Attach the 4 claws to install the duct. 16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY (a) Attach the 4 claws to install the nozzle. 17. INSTALL AIR CONDITIONING UNIT (a) Install the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Installation. Page 6705 Page 1786 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 5288 Drive/Propeller Shaft: Overhaul Disassembly PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: DISASSEMBLY 1. REMOVE FRONT PROPELLER SHAFT JOINT SPIDER BEARING SNAP RING (a) Place matchmarks on the flange yoke. (b) Using a brass bar and hammer, slightly tap in the spider bearing outer races. (c) Using needle-nose pliers, remove the 4 snap rings from the grooves. 2. REMOVE SPIDER BEARING (a) Using SST, push out the bearing from the flange yoke. SST : 09332-25010 HINT Before installing SST, sufficiently raise the part labeled A. If part A is too low, SST may be difficult to install. (b) Clamp the spider bearing outer race in a vise and tap off the propeller shaft with a hammer. NOTICE: EFI Relay Fuel Pump Relay: Testing and Inspection EFI Relay 1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (EFI) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the EFI No. 1 fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the EFI No. 1 fuse. (b) Measure the resistance of the EFI relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Regular Cab Fuel Pump Control Unit: Locations Regular Cab Body Page 5973 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 8718 Amplifier: Service and Repair Installation AUDIO / VISUAL: STEREO COMPONENT AMPLIFIER: INSTALLATION 1. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY (a) Set the bracket's aligning protrusion labeled A into the floor's hole. (b) Install the amplifier with the 3 bolts. HINT Tighten the bolts in the order shown in the illustration. (c) Connect the 3 connectors. 2. INSTALL AUDIO AMPLIFIER COVER (a) Set the cover on the stereo amplifier assembly. (b) Attach the 3 clips. 3. INSTALL FRONT SEAT ASSEMBLY RH (a) for Manual Seat: Install the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. (b) for Power Seat: Install the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 1903 Coolant: Service and Repair 1UR-FE COOLING: COOLANT: REPLACEMENT 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement 2. DRAIN ENGINE COOLANT CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. HINT Collect the coolant in a container and dispose of it according to the regulations in your area. (a) Loosen the radiator drain cock plug. (b) Remove the radiator cap. Then drain the coolant from the radiator. (c) Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine. (d) Tighten the 2 cylinder block drain cock plugs. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (e) Tighten the radiator drain cock plug by hand. 3. ADD ENGINE COOLANT (a) Add engine coolant. Standard Capacity: NOTICE: Do not substitute plain water for engine coolant. HINT TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids). Page 3231 Push the terminal retainer down to the temporary lock position. Page 410 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 167 Hazard Flasher Relay: Diagrams Page 3538 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (BUS BUFFER ECU BRANCH WIRE) (a) Disconnect the J59 bus buffer ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE BUS BUFFER ECU BRANCH WIRE OR CONNECTOR (CAN+, CAN-) OK -- REPLACE BUS BUFFER ECU Center Airbag Sensor Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Center Airbag Sensor Communication Stop Mode - Center Airbag Sensor Communication Stop Mode Page 6824 Page 8441 (a) Remove the antenna pole by turning it counterclockwise. Installation AUDIO / VISUAL: RADIO ANTENNA POLE: INSTALLATION 1. INSTALL PULL TOP ANTENNA POLE SUB-ASSEMBLY (a) Install the antenna pole by turning it clockwise. Page 152 Backup Lamp Relay: Diagrams Recall - Accelerator Pedal Modification Technical Service Bulletin # SC-A0A Date: 110219 Page 7659 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 271 "Case2" 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 1305 Page 4100 Positive Crankcase Ventilation Valve: Service and Repair Removal 1UR-FE EMISSION CONTROL: PCV VALVE: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE NO. 4 ENGINE COVER (a) Remove the No. 4 engine cover. 3. REMOVE NO. 3 ENGINE COVER (a) Remove the No. 3 engine cover. 4. DISCONNECT PCV VALVE HOSE 5. REMOVE PCV VALVE SUB-ASSEMBLY (a) Remove the PCV valve. Page 3437 Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (ECM) OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR 23. CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER) (a) Disconnect the J19 air conditioning amplifier connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING AMPLIFIER (CANH, CANL) OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY 24. CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU) (a) Disconnect the J59 bus buffer ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+, CAN-) Page 304 Engine Room R/B And Engine Room J/B Inner Circuit Page 6545 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 950 Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 6937 Driver Side J/B - Cowl Side Left Components Steering Column Control Module: Service and Repair Components STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): COMPONENTS Page 4466 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 1237 Page 6518 Page 3389 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 6814 Page 2575 Variable Valve Timing Actuator Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION 1. INSTALL VVT SENSOR (a) Install the 4 sensors with the 4 bolts. Components Four Wheel Drive Selector Switch: Service and Repair Components JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS Page 473 Seat Occupant Classification Module - Air Bag: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 3921 Page 2441 Oil Pressure Sender: Service and Repair Removal 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement 2. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Disconnect the sender gauge connector. (b) Remove the oil pressure sender gauge. Page 3062 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 7994 Page 3476 Page 7934 Seat)/Removal for power seat). HINT Keep the front seat in the cabin. (e) Install SST. (1) Disconnect the connector (yellow colored) from the front seat side airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect SST connector to the front seat side airbag connector. SST : 09082-00700 SST : 09082-00820 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation for manual seat, See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation for power seat). (4) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window. (5) Maintaining enough clearance for SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage SST wire harness. (6) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press SST activation switch and deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag. * Do not apply water to a front seat side airbag with a deployed airbag. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Transmission Control Switch Transmission Mode Switch: Diagrams Transmission Control Switch 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 7027 for CrewMax of standard deck Page 973 Dimmer Switch: Service and Repair Removal METER: LIGHT CONTROL RHEOSTAT: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE LIGHT CONTROL RHEOSTAT (a) Detach the 2 claws and remove the rheostat. Locations Tire Pressure Sensor: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 4751 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 3096 Ignition Switch: Testing and Inspection 1UR-FE STARTING: IGNITION SWITCH: INSPECTION 1. INSPECT IGNITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the ignition switch assembly. Page 3712 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. EFI Relay Fuel Pump Relay: Testing and Inspection EFI Relay 1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (EFI) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the EFI No. 1 fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the EFI No. 1 fuse. (b) Measure the resistance of the EFI relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Locations Overdrive Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 7779 (a) Install the filter as shown in the illustration. 15. INSTALL AIR FILTER COVER PLATE (a) Attach the 2 clips to install the plate. 16. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY (a) Attach the 4 claws to install the duct. 17. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY (a) Attach the 4 claws to install the nozzle. Page 3382 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 4760 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 6744 Junction Connector (CAN No.2) - Lower Finish Panel Page 4423 Fuel Pump Control Unit: Diagrams Up to 11/2009 Parking Brake Warning Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 1392 NOTICE: * If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the front airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (e) Check that there is no looseness in the installation parts of the front airbag sensor. 2. INSTALL BATTERY (a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the battery in place. (b) Connect the cable to the positive (+) battery terminal. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 6638 Auxiliary Power Outlet: Service and Repair Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Page 2039 Engine Room R/B And Engine Room J/B Inner Circuit Page 4521 Page 9242 REAR DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Connect the 2 cables to the inside handle. (b) Attach the inside handle's knob to the door trim board. (c) for 12 Speakers: (1) Connect the connector. (d) Attach the 10 clips to install the door trim board. (e) Install the inside handle and door trim board to the door trim panel with the screw. (f) Install the door trim board to the door panel with the screw. (g) Install the clip. 2. INSTALL REAR DOOR ARMREST COVER LH 3. INSTALL COURTESY LIGHT ASSEMBLY (a) Connect the connector. Page 6357 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 2308 * Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing. (d) Tighten the 10 bolts in the order shown in the illustration. Torque : 16 Nm (163 kgf-cm, 12 ft-lbf) NOTICE: Thoroughly wipe clean any seal packing. 3. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (a) Install the chain tensioner with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) While pushing down the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to fix it in place. 4. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH (a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. (b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. (c) Align the No. 2 chain's yellow mark plates with the timing marks of the camshaft timing gear and camshaft timing exhaust gear, and attach the No. 2 chain to the gears as shown in the illustration. Page 5041 5. INSTALL DIFFERENTIAL RING GEAR (a) Clean the contact surfaces of the differential case and ring gear. (b) Heat the ring gear to approximately 100°C (212°F) in boiling water. (c) Carefully take the ring gear out of the boiling water. (d) After the moisture on the ring gear has completely evaporated, quickly set the ring gear onto the differential case. HINT Align the matchmarks on the ring gear and differential case. (e) After the ring gear cools down sufficiently, apply adhesive to the bolts and install them. Adhesive: Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent Torque : 137 Nm (1397 kgf-cm, 101 ft-lbf) 6. INSPECT DIFFERENTIAL RING GEAR RUNOUT (a) Install the differential case onto the carrier, and install the 2 adjusting nuts so that there is no play in the bearing. (b) Install the 2 bearing caps with the 4 bolts. Page 1792 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 6796 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Components Tire Pressure Warning Reset Switch: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS Removal and Replacement Alternator: Removal and Replacement Components 1UR-FE CHARGING: GENERATOR: COMPONENTS Removal Locations Transmission Speed Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1111 Interior Light Switch: Service and Repair Removal LIGHTING: ROOM LIGHT SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE ROOM LIGHT SWITCH ASSEMBLY (a) Detach the 2 claws and remove the light switch. Up to 11/2009 Acceleration/Deceleration Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION A760F Automatic Transmission System Control Module: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 6039 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. Page 6116 NOTICE: While holding down the lead wire, remove the starter commutator end frame. 3. REMOVE STARTER BRUSH HOLDER ASSEMBLY (a) Using a screwdriver, pry the end of the spring away from each brush and pull out the 4 brushes from the brush holder so that they are held in place by the springs. (b) Remove the brush holder. 4. REMOVE STARTER ARMATURE ASSEMBLY (a) Remove the starter armature from the starter yoke. 5. REMOVE STARTER ARMATURE PLATE (a) Remove the starter armature plate from the starter drive housing or starter yoke. 6. REMOVE PLANETARY GEAR (a) Remove the 3 planetary gears from the starter center bearing clutch. 7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Remove the starter center bearing clutch with the starter pinion drive lever and rubber seal from the starter drive housing. (b) Remove the starter pinion drive lever and rubber seal from the starter center bearing clutch. Reassembly Page 6715 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 8255 (a) for Manual Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. (b) for Power Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 3. REMOVE FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Partially remove the front door opening trim weatherstrip so that the lower quarter trim panel assembly can be removed See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. 5. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 6. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 7. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 8. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY (a) Detach the 2 claws and remove the cover. (b) Remove the bolt and seat belt anchor. (c) Detach the 7 clips and remove the quarter trim panel. Page 7735 (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. 11. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 12. REMOVE BLOWER CASE SUB-ASSEMBLY (a) Remove the 3 screws. (b) Detach the 2 claws and remove the case. 13. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY Page 712 Reclining switch (b) If the result is not as specified, replace the switch. 2. INSPECT FRONT POWER SEAT SWITCH RH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Slide switch Page 4139 Page 7631 Page 4143 Page 5220 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 1401 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 5573 Acceleration/Deceleration Sensor: Service and Repair Installation BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION 1. INSTALL YAW RATE SENSOR (a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of the sensor bracket. (b) Install the yaw rate sensor with the 2 nuts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * Make sure that the sensor is oriented correctly. * If the sensor is dropped, replace it. * Securely connect the connector. * When installing the sensor, make sure to avoid impacts to the sensor. 2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation 3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration See: Testing and Inspection/Programming and Relearning. 6. CHECK YAW RATE SENSOR SIGNAL (a) Check the yaw rate sensor signal See: Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Specifications Brake Fluid: Specifications Brake Fluid Type ..................................................................................................................................................... .................... SAE J1703 or FMVSS No. 116 DOT 3 Locations Transmission Speed Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 7297 HINT Align the claws of the claw washers with the power steering rack grooves. (b) Using 2 SST, install the 2 steering rack ends. SST : 09922-10010 without SST - Torque : 195 Nm (1988 kgf-cm, 144 ft-lbf) with SST - Torque : 142 Nm (1448 kgf-cm, 105 ft-lbf) NOTICE: Turn SST 09922-10010 in the direction shown in the illustration. HINT * Using SST, hold the power steering rack and install the rack end sub-assembly. * Use a torque wrench with a fulcrum length of 345 mm (13.6 in.). (c) Using a brass bar and hammer, stake the 2 claw washers. NOTICE: Avoid any impact to the power steering rack. 12. INSPECT STEERING RACK END SUB-ASSEMBLY (a) Ensure that the steering rack end hole is not clogged with grease. HINT If the hole is clogged, the pressure inside the boot will change after it has been assembled, when the steering wheel is turned. 13. INSTALL STEERING RACK BOOT NO. 1 14. INSTALL STEERING RACK BOOT NO. 2 15. INSTALL STEERING RACK BOOT NO. 1 CLAMP (a) Using SST, tighten the rack boot No. 1 clamp as shown in the illustration. Specifications Spark Plug: Specifications SPARK PLUG Using a 16 mm plug wrench, install the 8 spark plugs. Torque.................................................................................................................................................. .....................................21 Nm (214 kgf-cm, 15 ft-lbf) GAP 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 7262 6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU (a) Disconnect the 2 ECU connectors. (b) Remove the 2 screws and ECU. Components Antenna, Navigation: Service and Repair Components NAVIGATION: NAVIGATION ANTENNA: COMPONENTS Page 3768 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 4402 Fuel Gauge Sender: Testing and Inspection 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSPECTION 1. INSPECT FUEL SENDER GAUGE ASSEMBLY (a) Check that the float moves smoothly between F and E. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the fuel sender gauge assembly. Page 1855 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 1703 (b) * for 5 leaf spring * If the toe-in is not as specified, adjust it at the rack ends. 4. ADJUST TOE-IN (a) Release the rack boot set 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 to the center value. (d) Check that the length of the right and left rack ends are approximately the same. Page 5153 Seals and Gaskets: Service and Repair Front Differential Side Gear Shaft Oil Seal Components DIFFERENTIAL: FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD): COMPONENTS Replacement DIFFERENTIAL: FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD): REPLACEMENT HINT The procedure described below is for the LH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. Page 15 Alarm Module: Locations Theft Deterrent System THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 4820 Transfer Case Actuator: Diagrams Page 5303 * Use new snap rings. * If possible, use snap rings of the same thickness for both sides. (f) Temporarily install the universal joint spider and 2 universal joint spider bearings into the propeller shaft yoke. (g) Using SST, press the universal joint spider bearing into the propeller shaft yoke until the groove can be seen. SST : 09950-40011 09951-04020 09952-04010 09953-04020 09954-04020 09955-04051 09957-04010 SST : 09950-60010 09951-00290 SST : 09336-16010 NOTICE: Confirm that the universal joint spider moves smoothly while pressing in the bearing. (h) Using needle-nose pliers, install the previously selected snap ring into the groove of the yoke. HINT Use the same installation procedure for the universal joint spider bearing on the opposite side. (i) Align the matchmarks on the propeller shaft yoke and universal joint yoke, and temporarily install the spider and 2 universal joint spider bearings into the universal joint yoke. (j) Using SST, press the universal joint spider bearing into the universal joint yoke until the groove can be seen. SST : 09950-40011 Page 677 Power Door Lock Switch: Service and Repair Unlock Warning Switch Components DOOR LOCK: UNLOCK WARNING SWITCH: COMPONENTS Removal DOOR LOCK: UNLOCK WARNING SWITCH: REMOVAL 1. REMOVE LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Page 4297 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 5546 Standard voltage: (3) If the voltage is not as specified, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. If the voltage is normal, replace the 4WD control switch. Page 9362 Parts Information Repair Procedure 1. Test-drive the vehicle and confirm the condition. NOTE Repeat remaining steps for both No.3 cab mounts. 2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is necessary to allow the cab to be raised to remove the No.3 mount. The cab mounts in the front are only loosened to allow the technician to raise the cab to install the rear cab mounts. Not necessary to change. Page 4144 Airbag Cut-OFF Switch Air Bag Deactivation Switch: Service and Repair Airbag Cut-OFF Switch Components SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Remove the lower No. 2 instrument panel airbag assembly See: Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal. 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE AIRBAG CUT-OFF SWITCH (a) Detach the 2 claws to remove the switch. Installation SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSTALLATION 1. INSTALL AIRBAG CUT-OFF SWITCH (a) Attach the 2 claws to install the switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Install the lower No. 2 instrument panel airbag assembly See: Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 1395 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 9084 Connectors Part 2 Page 6270 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Air Fuel Ratio Sensor Oxygen Sensor: Diagrams Air Fuel Ratio Sensor Page 8071 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 6284 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 2360 Page 6367 Engine Room Main Wire Page 2000 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. Page 1861 Step 6. Pull the filter out of the filter outlet. Cleaning method. Page 5814 Brake Fluid Pump Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 6467 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 7992 CAUTION: Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. 1. INSTALL FRONT SEAT SIDE AIRBAG ASSEMBLY CAUTION: * The nuts must not be reused. * Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one. (a) Install the front seat side airbag assembly with 2 new nuts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) (b) Connect the clamp. 2. INSTALL FRONT SEATBACK COVER WITH PAD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 3. INSTALL FRONT SEATBACK LOCK SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 4. INSTALL FRONT SEATBACK LOCK HANDLE ROD See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 5. INSTALL FRONT SEATBACK LOCK SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 6. INSTALL FRONT SEATBACK BOARD See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 7. INSTALL FRONT SEATBACK ASSEMBLY RH (a) Install the seatback with the 4 bolts. Torque : 43 Nm (438 kgf-cm, 32 ft-lbf) (b) Connect the 3 airbag wire harness clamps to under the seat. Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 8818 Removal AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly Components Power Steering Pressure Switch: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: COMPONENTS Page 9119 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 6615 Power Outlet Socket (115V) Page 2260 (h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for work that can be finished quickly. Safety stands must be used to support the vehicle. Page 4218 Accelerator Pedal: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: ON-VEHICLE INSPECTION 1. INSPECT ACCELERATOR PEDAL ROD ASSEMBLY (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. (c) Turn the Techstream main switch ON. (d) Enter the following menus: Powertrain / Engine and ECT / Data List / ALL Date / Accel Sensor Out No. 1 and Accel Sensor Out No. 2. (e) Read the value displayed on the tester. Standard Voltage: Accel Sensor Out No. 1 Accel Sensor Out No. 2 (f) If the result is not as specified, check the accelerator pedal rod, wire harness or ECM. Page 2981 Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch Page 5066 Standard backlash: 0.1 to 0.25 mm (0.00394 to 0.00984 in.) (2) If the backlash is not within the specification, install a side gear thrust washer with a different thickness. (d) Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft. (e) Stake the differential case. 8. INSTALL DIFFERENTIAL RING GEAR (a) Clean the contact surfaces of the differential case and ring gear. (b) Heat the ring gear to about 100C (212F) in boiling water. (c) Carefully take the ring gear out of the boiling water. (d) After the moisture on the ring gear has completely evaporated, quickly set the ring gear onto the differential case. HINT * Align the matchmarks on the ring gear and differential case. * Temporarily install the 10 bolts so that the bolt holes in the ring gear and differential case are aligned. (e) After the ring gear cools down sufficiently, apply adhesive to the bolts and install them. Torque : 137 Nm (1397 kgf-cm, 101 ft-lbf) Adhesive: Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent 9. INSTALL FRONT DIFFERENTIAL CASE BEARING (a) Using SST and a press, press in the 2 bearings (inner race). SST : 09316-20011 SST : 09316-60011 09316-00041 Page 6476 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 3486 NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (CENTER AIRBAG SENSOR) OK -- REPLACE CENTER AIRBAG SENSOR 12. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU) NOTICE: For vehicles without 4WD, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU)". (a) Disconnect the A25 4WD control ECU connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU) A -Continue to next step. 13. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (4WD CONTROL ECU) OK -- REPLACE 4WD CONTROL ECU 14. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU) NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE)". (a) Disconnect the J101 power steering ECU connector. Page 6192 Installation OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION 1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply) (a) Attach the 2 claws to install the power outlet socket. 2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard) (a) Attach the 2 claws to install the power outlet socket cover. 3. INSTALL REAR POWER OUTLET SOCKET (for Standard) (a) Attach the claw to install the power outlet socket. 4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL Page 3536 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE) (a) Disconnect the J19 air conditioning amplifier connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE AIR CONDITIONING AMPLIFIER BRANCH WIRE OR CONNECTOR (CANH, CANL) Page 2135 Tire Pressure Module: Diagrams Page 5800 Vacuum Brake Booster: Testing and Inspection BRAKE: BRAKE BOOSTER: ON-VEHICLE INSPECTION 1. INSPECT BRAKE BOOSTER (a) OPERATING CHECK (1) Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. (2) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. (b) AIRTIGHTNESS CHECK (1) 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 airtight. (2) 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 airtight. 2. CHECK BRAKE VACUUM CHECK VALVE ASSEMBLY (a) Check the check valve. (1) Slide the clip and disconnect the vacuum hose. (2) Remove the check valve from the booster. (3) Check that there is ventilation from the booster to the engine, and no ventilation from the engine to the booster. If the results are not as specified, replace the check valve assembly. Page 8016 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 5965 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 8777 Rear Door Speaker Woofer Page 3420 2. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU) (a) Disconnect the J2 main body ECU connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH ACTUATOR) A -- Continue to next step. 3. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (MAIN BODY ECU) OK -- REPLACE MAIN BODY ECU 4. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A17 skid control ECU with actuator connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR) Front Door Lock Switch Power Door Lock Switch: Diagrams Front Door Lock Switch Page 8154 2. INSTALL FRONT SEAT ASSEMBLY LH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Installation. 3. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 5274 (a) Align the matchmarks on the propeller shaft flange and differential flange. (b) Install the propeller shaft to the differential side with the 4 bolts and 4 nuts. Torque : 70 Nm (714 kgf-cm, 52 ft-lbf) (c) Align the matchmarks on the propeller shaft flange and transfer flange. (d) Install the propeller shaft to the transfer side with the 4 nuts. Torque : 70 Nm (714 kgf-cm, 52 ft-lbf) 2. MEASURE TRANSFER AND DIFFERENTIAL FLANGE ANGLE (for 3 Joint Type) NOTICE: * Perform the inspection on a level surface. * Perform the inspection with the vehicle empty. * Perform the inspection with all wheels on the ground. HINT As the transfer and rear differential flange angles are necessary when measuring the installation angle of the propeller shaft, measure the angle of the transfer and rear differential flange before installing the propeller shaft. (a) Using SST, measure and record the angle of the transfer flange (A). SST : 09370-50010 Page 5122 Production Change Information This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below. Parts Information Required Tools & Equipment Inspection Procedure 1. Test drive the vehicle and confirm the noise is only present in 4WD. 2. Place the vehicle on the lift and remove the left front wheel. Page 8531 (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY Page 8788 1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 10 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Front Door Speaker (for Regular Cab) Page 7216 6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU (a) Disconnect the 2 ECU connectors. (b) Remove the 2 screws and ECU. Page 6408 Page 1660 Washer Fluid Level Switch: Diagrams Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2068 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 3577 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Page 343 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Front Power Seat Control System (w/ Memory) Power Seat Switch: Locations Front Power Seat Control System (w/ Memory) SEAT: FRONT POWER SEAT CONTROL SYSTEM (w/ Memory): PARTS LOCATION Page 1631 Power Window Switch: Diagrams Power Window Regulator Switch (for Back Window) Page 3619 5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor connector. (b) Disconnect the air fuel ratio sensor connector. (c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support. (d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH. 7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) for 2WD: Disconnect the air fuel ratio sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION 1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 Page 5304 09951-04020 09952-04010 09953-04020 09954-04020 09955-04051 09957-04010 SST : 09950-60010 09951-00290 SST : 09336-16010 (k) Using needle-nose pliers, install the previously selected snap ring into the groove on the universal joint yoke. HINT Use the same installation procedure for the universal joint spider bearing on the opposite side. 4. INSTALL PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Check the spider bearings for wear and damage. (b) Measure each spider bearing's axial play by turning the yoke while holding the shaft tightly. Maximum bearing axial play: 0.05 mm (0.00197 in.) Page 6004 Parking and Paint Protection ^ Storage areas should be paved, well lit and secure. If your off-site storage lot is not paved, spread gravel down to minimize mud and dust. Be sure vehicles are driven carefully when moving them to or from a long-term lot. This will help minimize damage to the paint finish from road grit or gravel. ^ Park vehicles from right to left at least three feet apart. Leave enough space front and rear to easily walk between rows. ^ HVAC vent controls should be set to "Recirc" to minimize dust and odor intrusion. ^ Make sure the plastic door edge protectors are in place and fold in the side view mirror (if applicable). ^ Anti-rust covers or anti-rust film should remain on vehicle during storage 1. Anti-Rust Covers (behind wheel) should be removed at PDS. 2. Anti-Rust Film (applied to wheel) should be removed just prior to customer delivery. ^ Wash vehicles frequently. Battery ^ Turn off all electrical accessories, make sure windows and sunroof are closed and check that the transmission is in "park" (first or reverse for manual transmission vehicles). Do not apply the parking brake. ^ Test batteries monthly (more often in high heat or cold areas), using the Digital Battery System ^ Analyzer (P/N 00002-V8150-KIT). Refer to TSB PG001-06, "Battery Maintenance for In Stock Vehicles and Pre-Delivery" for complete battery maintenance procedures. ^ To reduce battery drain during long-term storage, remove the battery ground (-) cable of each vehicle and reinstall just before delivery to the customer. Locate the current PDS TSB on TIS for complete details. ^ If a hybrid vehicle is put into storage, the state of charge (SOC) of it's battery and auxiliary battery will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage, proper maintenance is necessary. Refer to TSB "Maintenance for HV & Auxiliary Batteries" for procedure and additional information. Tire Inflation Pressure If the vehicle is parked for long periods without being moved, a flat spot may develop on each tire surface in contact with the ground, even if the tires are inflated to specification. Tire inflation pressure should be checked once a month. Tire inflation pressure for storage only: 45 psi. Parts Rust If the vehicles in your storage area are exposed to a sea breeze and/or a significant precipitation corrosion with rust in some parts may occur. If rust is found remove it and treat it by applying rust inhibitor to prevent recurrence. Engine Starting and Vehicle Movement If the vehicle is stored over an extended period of time starting and running the engine periodically will ensure smooth running operation. 1. Start and operate the engine at an engine speed under 1,500 RPM for 15 minutes or longer. This also eliminates moisture in the exhaust system. NOTE Be sure to allow sufficient clearance at the rear of the vehicle to prevent other vehicles stored behind from getting damaged by exhaust gas. 2. Move the vehicle at least 30 feet to lubricate the transmission and differential and prevent tire flat-spot damage. 3. Raise engine speed above 3,000 RPM 10 times to eliminate moisture from the exhaust. A/C Compressor Lubrication To minimize the possibility of damage to the A/C compressor while storing a vehicle perform the following recommended maintenance procedures at Page 1225 Power Steering Pressure Switch: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install a new O-ring to the power steering oil pressure switch. (b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch. NOTICE: * When reusing the power steering oil pressure switch, inspect the O-ring. * If the O-ring has scratches or cuts, replace the power steering oil pressure switch. (c) Using SST, install the power steering oil pressure switch. SST : 09922-10010 without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the torque wrench are connected in a straight line. (d) Connect the oil pressure switch connector. 2. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 3. ADD POWER STEERING FLUID 4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 5. INSPECT FOR POWER STEERING FLUID LEAK 6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Page 9085 Connectors Part 3 Page 1368 (b) Detach the 2 claws and remove the switch. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: INSTALLATION 1. INSTALL CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Attach the 2 claws to install the switch. (b) Connect the connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 987 Page 7037 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 2998 Page 9303 Page 1953 * Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat. * Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass. 3. WARM UP ENGINE (a) Warm up the engine at less than 1500 rpm for 1 minute or more after charging the refrigerant. NOTICE: Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor. 4. CHECK FOR REFRIGERANT GAS LEAK (a) After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector. (b) Perform the operation under the following conditions: * The ignition switch is OFF. * The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. * Some refrigerant is remaining in the refrigerant system. * The compressor is off and its pressure is approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi). (c) Using a halogen leak detector, check the refrigerant line for leakage. (d) If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test. (e) Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test. Page 7040 *: for 5 leaf spring Page 1739 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Page 6741 J/B No.4 - Instrument Panel Center Page 4087 EGR Valve: Testing and Inspection 1UR-FE EMISSION CONTROL: EGR VALVE: INSPECTION 1. INSPECT EGR VALVE ASSEMBLY (a) Check the resistance of the EGR valve. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the EGR valve. Page 2056 Relay Box: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 7576 Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. Component Tests and General Diagnostics Acceleration/Deceleration Sensor: Component Tests and General Diagnostics BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION 1. CHECK YAW RATE SENSOR (a) Check the yaw rate sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 8355 Impact Sensor: Service and Repair Side Airbag Sensor (for Double Cab) Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): COMPONENTS Page 5655 Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) NOTICE: * Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part. * While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip part. * After installing the speed sensor, make sure there is no clearance or foreign matter between the sensor stay part and the knuckle. * Make sure there is no foreign matter attached to the magnetic rotor. 6. INSTALL FRONT SKID CONTROL SENSOR WIRE RH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). for Bolt B - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Install the connector (labeled C) with connect the connector (labeled C). (c) Install the 2 harness clamps (labeled D) with the 2 bolts (labeled E). for Bolt E - Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamps, do not twist the wire harness. * For clamps with rotation stoppers, make sure the rotation stopper touches the installation position. (d) Install the harness clamp with the bolt (labeled E). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamp, do not twist the wire harness. * Make sure the clamp's rotation stopper touches the installation position. Page 385 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 6. INSPECT IGNITION SWITCH See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0617 NG -- REPLACE IGNITION SWITCH See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Service and Repair/Removal OK -- Continue to next step. 7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the cable from the battery positive terminal. (c) Remove the integration relay from the engine room relay block. (d) Disconnect the integration relay connectors. Page 6240 Engine Room R/B, J/B - Engine Compartment Left Page 4362 Fuel Pressure Regulator: Service and Repair Removal 1UR-FE FUEL: FUEL PRESSURE REGULATOR: REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE See: Fuel Injector/Service and Repair/Removal 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE V-BANK COVER See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 4. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 5. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY (a) Disconnect the No. 2 fuel tube from the pressure regulator See: Service Precautions. CAUTION: Put a cloth or equivalent under the pressure regulator. (b) Disconnect the vacuum sensing hose from the pressure regulator. (c) Remove the 2 bolts, and pull out the pressure regulator. (d) Remove the O-ring from the pressure regulator. Page 2866 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay 1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION 1. REMOVE FUEL PUMP RELAY (F/PMP) (a) Remove the fuel pump relay from the engine room relay block. 2. INSPECT FUEL PUMP RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the fuel pump relay. 3. INSTALL FUEL PUMP RELAY (a) Install the fuel pump relay to the engine room relay block. Page 6791 Push the terminal retainer down to the temporary lock position. Locations Door Switch: Locations DOOR LOCK: KEY REMINDER WARNING SYSTEM: PARTS LOCATION Page 334 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 8821 Repair/Front Door (for Double Cab)/Reassembly 8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): COMPONENTS Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Pump: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 5659 1. INSTALL SKID CONTROL SENSOR WIRE (a) Install the sensor clamp with the nut (labeled A). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Make sure the clamp's rotation stopper touches the installation position. (b) Install the sensor clamp with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: When installing the clamp, do not twist the wire harness. (c) Attach the 7 clips (labeled C). NOTICE: * When installing the clamps, do not twist the wire harness. * When installing the clamps, securely insert them as shown in the illustration. (d) Connect the sensor connector (labeled D). NOTICE: Securely connect the connector. 2. INSTALL REAR SPEED SENSOR LH (a) Install the speed sensor (labeled A) with the nut (labeled B). Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Connect the speed sensor connector (labeled C). NOTICE: Securely connect the connector. 3. INSTALL REAR SPEED SENSOR RH (a) Install the speed sensor (labeled A) with the nut (labeled B). Page 5367 Standard resistance: (4) If the resistance is not as specified, repair or replace the harness or connector. (c) Check the 4WD control switch. (1) Turn the ignition switch OFF. (2) Connect the L1 switch connector. (3) Connect the A25 and A26 ECU connectors. (4) Measure the voltage according to the value(s) in the table below. Standard voltage: (5) If the voltage is not as specified, check the 4WD control ECU. (d) Check the 4WD control ECU. (1) Disconnect the L1 switch connector. (2) Measure the voltage according to the value(s) in the table below. Page 2255 * The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL LH 2. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 3. REMOVE REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Removal 4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 5. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 6. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 7. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 8. REMOVE REAR AXLE LH HUB BOLT (a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the hub bolt. SST : 09650-17011 9. INSTALL REAR AXLE LH HUB BOLT (a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration. NOTICE: Install hub nuts to prevent damage to the hub bolts. (b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of the hub bolt head touches the axle hub. (c) Remove the washer and hub nut. NOTICE: Do not damage the threads of the hub bolts. 10. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 11. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly Page 2224 Tire Pressure Adjustment Recommended Tire Pressure Adjustment: NOTE Use a high quality accurate tire pressure gauge, and check its accuracy regularly. ^ Consider the difference of the air temperature in the workshop and the lowest ambient temperature that may be expected in the next few weeks (especially in winter). ^ Use the chart (Figure 1) to compensate for temperature of the tires when adjusting tire pressure. Use temperature compensation Example 1 for the spare tire. Example 1: Temperature Compensation - "Cold" Tires ^ The vehicle has been parked overnight outside shop (vehicle has "cold" tires) and tire pressures are set to 31.9 psi. ^ Workshop temperature is 68°F and expected lowest ambient temperature in the local area is to be 14°F. ^ Subtract the expected lowest temperature (14 F) from the workshop temperature (68°F) = 54°F. ^ Using the tire pressure chart (Figure 1) find the intersection of the cold tire line at the point corresponding to 54°F and read oft the value on the tire pressure change axis. In this case it would be about 4.9 psi. ^ The tires should be filled to: 31.9 + 4.9 psi = 36.8 psi Example 2: Temperature Compensation - "Warm" Tires ^ The vehicle has been driven to the shop on surface streets for about 30 minutes (vehicle has "warm" tires) and tire pressures are set to 31.9 psi. ^ Workshop temperature is 68 F and expected lowest ambient temperature in your area is to be 14°F. Page 9180 5. REMOVE NO. 2 SIDE STEP BRACKET LH (a) Remove the 2 bolts and side step bracket. 6. REMOVE NO. 3 SIDE STEP BRACKET LH (a) Remove the 4 bolts and 2 side step brackets. Reassembly EXTERIOR: SIDE STEP: REASSEMBLY 1. INSTALL NO. 3 SIDE STEP BRACKET LH (a) Install the 2 side step brackets with the 4 bolts. Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) 2. INSTALL NO. 2 SIDE STEP BRACKET LH (a) Install the side step bracket with the 2 bolts. Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) Page 4426 Fuel Pump Control Unit: Service and Repair Removal 1UR-FE FUEL: FUEL PUMP ECU: REMOVAL 1. REMOVE FUEL PUMP ECU (a) Disconnect the 2 fuel pump ECU connectors. (b) Remove the 2 bolts and fuel pump ECU. NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being dropped, etc. Page 1042 Cargo Lamp Switch: Service and Repair Removal LIGHTING: CARGO LIGHT SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE CARGO LIGHT SWITCH (a) Detach the 2 claws and remove the light switch. Page 2037 Junction Connector (CAN No.2) - Lower Finish Panel Page 6721 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 6975 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 2897 Air Flow Meter/Sensor: Diagrams Page 8948 3. INSTALL FRONT BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 4. INSTALL FRONT END PANEL LH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 5. INSTALL FRONT END PANEL RH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 6. INSTALL FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 7. INSTALL FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 8. INSTALL FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 9. INSTALL FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 10. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 11. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. ADJUST FOG LIGHT (a) Adjust the fog light See: Lighting and Horns/Fog/Driving Lamp/Adjustments. Page 2716 Removal 1UR-FE EXHAUST: EXHAUST PIPE (except Regular Cab Standard Deck): REMOVAL CAUTION: * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE TAILPIPE ASSEMBLY (a) Remove the bolt, clamp and gasket. (b) Disconnect the tailpipe from the exhaust pipe support. 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY (a) Remove the 4 bolts. (b) Disconnect the center exhaust pipe from the 3 exhaust pipe supports. (c) Remove the center exhaust pipe from the front exhaust pipe and front No. 2 exhaust pipe. Page 6295 Driver Side J/B - Cowl Side Left Page 2029 Engine Room R/B, J/B - Engine Compartment Left Page 268 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 5443 (4) If the resistance is not as specified, repair or replace the harness or connector. (c) Check the 4WD control switch. (1) Turn the ignition switch OFF. (2) Connect the L1 switch connector. (3) Connect the A25 and A26 ECU connectors. (4) Measure the voltage according to the value(s) in the table below. Standard voltage: (5) If the voltage is not as specified, check the 4WD control ECU. (d) Check the 4WD control ECU. (1) Disconnect the L1 switch connector. (2) Measure the voltage according to the value(s) in the table below. Page 50 Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation Page 4633 Spark Plug: Service and Repair Installation 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION 1. INSTALL SPARK PLUG (a) Using a 16 mm plug wrench, install the 8 spark plugs. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 2. INSTALL IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors. (3) Connect the 3 wire harness clamps. (b) for Bank 2: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors and 2 wire harness clamps. (3) Connect the water by-pass pipe with the 2 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) Specifications Spark Plug: Specifications SPARK PLUG Using a 16 mm plug wrench, install the 8 spark plugs. Torque.................................................................................................................................................. .....................................21 Nm (214 kgf-cm, 15 ft-lbf) GAP Page 990 Door Switch: Service and Repair Rear Door Courtesy Switch Components LIGHTING: REAR DOOR COURTESY SWITCH: COMPONENTS Page 3290 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 8699 Seat Memory Switch: Testing and Inspection SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSPECTION 1. INSPECT SEAT MEMORY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 7080 (a) Attach the claw to install the upper steering column cover. (b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish panel. (c) Install the 2 screws. Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf) HINT Turn the steering wheel to the right and left as necessary to install the 2 screws. 8. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 4819 Page 4941 Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L bracket of the cable faces the inside of the vehicle. (g) Connect the transmission control cable support with the nut. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) 2. ADJUST SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type) 3. INSPECT SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type) 4. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL CONSOLE BOX CARPET 7. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 11. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 12. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 13. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 1696 *: for 5 leaf spring Page 2223 Introduction The purpose of this bulletin is to provide a procedure to adjust tire pressure correctly when outside temperature is significantly colder or warmer than shop temperature. Seasonal temperature change can dramatically alter tire pressure, which can cause the tire pressure warning lamp to illuminate. NOTE This bulletin applies to some 2004 - 2007 model year Toyota vehicles with direct TPWS and all 2008 and newer model year Toyota vehicles. Warranty Information Tire Pressure vs. Tire Temperature Tire temperature is dependent on "cold" tire pressure, driving distance and speed, ambient temperature and road surface temperature. As the temperature of the tire changes, air in the tire expands and contracts, changing the tire's air pressure. The cold tire pressure for all Toyota models will vary and will need to be adjusted accordingly. "Cold" tire pressure, as shown on the tire pressure label on our vehicles, is generally considered to be the pressure in a tire that has not been driven in the past 4 hours and has been parked outdoors. The TPWS MUST be initialized with the tire pressure marked on the vehicle placard. Tires are then adjusted according to the information in this bulletin to ensure that the TPWS light does not illuminate unnecessarily. Locations Power Distribution Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 6581 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 8575 3. INSTALL FRONT BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 4. INSTALL FRONT END PANEL LH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 5. INSTALL FRONT END PANEL RH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 6. INSTALL FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 7. INSTALL FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 8. INSTALL FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 9. INSTALL FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation 10. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 11. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. ADJUST FOG LIGHT (a) Adjust the fog light See: Lighting and Horns/Fog/Driving Lamp/Adjustments. Page 1650 HINT Tape the screwdriver tip before use. (b) Disconnect the master switch connector. 2. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Remove the 3 screws and master switch. Installation WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: INSTALLATION 1. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Install the master switch with the 3 screws. Page 7797 Refrigerant Pressure Sensor / Switch: Diagrams Page 6389 Page 3478 2. CLEAR DTC (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch ON. (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Main Body / Trouble Codes. (e) Clear the DTCs. Problem Symptoms Table MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS TABLE HINT * Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. * Inspect the fuses and relays related to the system before inspecting the suspected areas below. Integration Control and Panel Assembly Communication Error MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: Integration Control and Panel Assembly Communication Error - Integration Control and Panel Assembly Communication Error DESCRIPTION The LIN communication of the components related to the mirror heater occurs between the air conditioning amplifier assembly (A/C ECU) and integration control and panel assembly. WIRING DIAGRAM INSPECTION PROCEDURE NOTICE: When using the Techstream with the ignition switch OFF to troubleshoot: Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6563 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 3732 (c) WAVEFORM 2: HINT The wavelength varies in accordance with the engine operating conditions. (d) WAVEFORM 3: HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the heated oxygen sensor. (e) WAVEFORM 4: Page 8797 Speaker: Service and Repair Floor Speaker (for Double Cab) Components AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): COMPONENTS Removal AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 733 Seat Heater Switch: Testing and Inspection SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System): INSPECTION 1. INSPECT SEAT HEATER SWITCH LH (w/ Seat Heater System) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: HINT As the dial is being turned, the resistance changes gradually. (b) If the result is not as specified, replace the switch. (c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. OK: (d) If the result is not as specified, replace the switch. (e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. OK: Removal and Replacement Housing Assembly HVAC: Removal and Replacement Components AIR CONDITIONING: AIR CONDITIONING UNIT: COMPONENTS Page 7639 "Case2" 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 Center Airbag Sensor Assembly (for Column Shift Type) Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 5709 Brake Bleeding: Service and Repair Replacement BRAKE: BRAKE FLUID: REPLACEMENT NOTICE: * Perform fluid replacement with the parking brake applied. * Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir. * Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off immediately. * Add fluid to the brake fluid reservoir as necessary so that the fluid does not decrease below the MIN level. 1. REPLACE BRAKE FLUID (a) Replace the brake fluid. (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (7) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. (10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (13)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (b) Check and bleed brake system. (1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform the following air bleed procedures. * Low pedal or spongy pedal. * Brake pedal is depressed firmly but braking is insufficient. (c) Inspect for the brake fluid leak. (d) Check and adjust brake fluid level in reservoir See: Brake Fluid/Testing and Inspection. Page 7852 Compressor Speed Sensor: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 6618 Power Outlet [12V] Locations Transmission Mode Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 6480 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 3431 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR) OK -- Continue to next step. 10. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - STEERING ANGLE SENSOR) (a) Disconnect the J87 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR) OK -- Continue to next step. 11. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - POWER STEERING ECU) NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)". (a) Disconnect the J115 No. 1 junction connector connector. Up to 11/2009 Steering Angle Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 2159 No further tightening is required once the nut is tightened with the specified torque. 2. INSTALL WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 3. INSPECT TIRE (a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics. 4. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration. 5. PERFORM INITIALIZATION (a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 6. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 1449 Seat Occupant Sensor: Diagrams Rear Occupant Classification Sensor Page 399 (q) WAVEFORM 16: HINT The wavelength changes when the air injection control driver detects malfunctions in the air injection system See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0412 (r) WAVEFORM 17: HINT The wavelength becomes shorter as engine rpm increases. (s) WAVEFORM 18: Page 2581 Fuel Pressure: Testing and Inspection 1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. NOTICE: Do not start the engine. (c) Turn the Techstream main switch ON. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (e) Check the fuel pump operation. (1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard. If there is no sound, check the integration relay, fuel pump, ECM and wiring connector. (f) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. 2. CHECK FUEL PRESSURE (a) Check that the battery voltage is 11 to 14 V. (b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions. (c) Disconnect the cable from the negative (-) battery terminal. (d) Remove the fuel pipe clamp from the fuel tube connector. (e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it. CAUTION: * Always read the precautions See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions before disconnecting the fuel tube connector (quick type). * The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. Page 5787 Parking Brake Warning Switch: Testing and Inspection PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake Pedal/Service and Repair/Overhaul/Disassembly 2. CHECK PARKING BRAKE SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the parking brake switch assembly. 3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake Pedal/Service and Repair/Overhaul/Reassembly Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 1854 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 2024 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 4609 Ignition Switch: Connector Views Locations Trailer Lighting Relay: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 6939 Driver Side J/B - Cowl Side Left Page 2605 (4) for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector. (5) for Fuel Hose Connector Cover Type: Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration. (6) Check that there is no fuel leakage. 3. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See: Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection. Page 1329 Page 3914 Variable Valve Timing Actuator: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. Page 8440 Antenna, Radio: Service and Repair Radio Antenna Pole Components AUDIO / VISUAL: RADIO ANTENNA POLE: COMPONENTS Removal AUDIO / VISUAL: RADIO ANTENNA POLE: REMOVAL 1. REMOVE PULL TOP ANTENNA POLE SUB-ASSEMBLY Page 5531 Transmission Speed Sensor: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION 1. INSTALL SPEED SENSOR SP2 (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. 2. INSTALL SPEED SENSOR NT (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. Page 6333 Components Fuel Pump Control Unit: Service and Repair Components 1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS Page 4862 Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch Page 3819 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Page 444 Ignition Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY (a) Remove the engine room relay block cover. (b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room relay block. HINT Tape the screwdriver tip before use. (c) Disconnect the 3 connectors. 2. INSPECT INTEGRATION RELAY (IG2) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the IG2 MAIN fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the IG2 MAIN fuse. (b) Measure the resistance of the ignition relay No. 2 (IG2). Page 3905 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 1423 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): COMPONENTS Page 5670 Page 6488 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 6628 2. REMOVE CONSOLE BOX BEZEL (a) Disconnect the connector. (b) Using a screwdriver, detach the 5 claws and remove the console box bezel. HINT Tape the screwdriver tip before use. 3. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 4. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. Page 4342 Page 6930 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 179 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 7039 for CrewMax of standard deck Page 6634 Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Crewmax Column Shift Type) Components OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS Removal OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL 1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly Page 4114 (4) for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector. (5) for Fuel Hose Connector Cover Type: Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration. (6) Check that there is no fuel leakage. 3. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See: Testing and Inspection. Occupant Classification System Air Bag Control Module: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 8400 Seat Occupant Sensor: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 8351 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 8013 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY Page 3537 OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY Bus Buffer ECU Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Bus Buffer ECU Communication Stop Mode - Bus Buffer ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM Page 7198 (c) Install the rear housing with the 4 bolts. Torque : 22 Nm (224 kgf-cm, 16 ft-lbf) 8. INSPECT TOTAL PRELOAD See: Testing and Inspection 9. INSTALL POWER STEERING SUCTION PORT UNION (a) Coat a new O-ring with power steering fluid and install it to the suction port union. (b) Install the suction port union to the vane pump with the bolt. Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) Page 3411 Page 6107 (2) If the result is not as specified, replace the starter armature assembly. (d) Using a vernier caliper, measure the commutator diameter. Standard diameter: 35.0 mm (1.38 in.) Minimum diameter: 34.0 mm (1.34 in.) (e) If the diameter is less than the minimum, replace the starter armature assembly. (f) Using a dial gauge, measure the commutator runout. Maximum commutator runout: 0.05 mm (0.00197 in.) (g) If the commutator runout is more than the maximum, correct it using a lathe. (h) Measure the undercut depth of the commutator. Standard undercut depth: 0.7 mm (0.0276 in.) Minimum undercut depth: 0.2 mm (0.00787 in.) Page 6017 1UR-FE CHARGING: GENERATOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 3. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Removal 4. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 5. DISCONNECT POWER STEERING OIL PRESSURE SWITCH CONNECTOR See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Removal and Replacement/Removal 6. DISCONNECT SOLENOID VALVE CONNECTOR See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Removal and Replacement/Removal 7. DISCONNECT VANE PUMP ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Removal 8. DISCONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ Trailer Towing System) See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 9. REMOVE GENERATOR ASSEMBLY (a) Remove the terminal cap. (b) Disconnect the generator connector. (c) Remove the nut and disconnect the generator wire. (d) Remove the bolt and disconnect the wire harness bracket from the generator. (e) Remove the 3 bolts, nut and generator. Installation 1UR-FE CHARGING: GENERATOR: INSTALLATION 1. INSTALL GENERATOR ASSEMBLY (a) Install the generator with the 3 bolts and nut. Page 3376 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 3590 (a) Disconnect the ECM connector. (b) Disconnect the combination meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 5. CHECK THAT MIL IS ILLUMINATED (a) Check if the MIL is illuminated when the ignition switch is turned to ON. OK: MIL should be illuminated. NG -- CHECK THAT ENGINE STARTS OK -- END 6. CHECK THAT ENGINE STARTS (a) Turn the ignition switch to ON. (b) Start the engine. Result HINT *: The Techstream cannot communicate with the ECM. Page 8018 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Page 5777 (b) Remove the clip. (c) Using a screwdriver, slowly bend up the claw. NOTICE: Be careful not to damage the No. 1 parking brake cable or claw. (d) Disconnect the parking brake cable from the parking brake control pedal. 7. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY (a) Disconnect the connector. (b) Detach the wire harness clamp from the control pedal. (c) Remove the 3 nuts and parking brake control pedal from the body. Page 830 Page 4602 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 3524 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH, CANL) OK -- REPLACE MAIN BODY ECU 15. CHECK FOR SHORT TO GND IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A17 skid control ECU with actuator connector. Page 8045 (3) After setting the spiral cable to the center position, rotate the spiral cable 2.5 times clockwise. Then while rotating the spiral cable 5 times counterclockwise, measure the resistance according to the U4 (uecs) in the table below. Standard resistance: NOTICE: As the spiral cable may break, do not rotate the spiral cable more than the specified amount. Page 3541 NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE CENTER AIRBAG SENSOR Combination Meter ECU Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Combination Meter ECU Communication Stop Mode - Combination Meter ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. CHECK HARNESS AND CONNECTOR (COMBINATION METER ECU - BATTERY AND BODY GROUND) (a) Disconnect the J28 combination meter ECU connector. Page 8476 Alarm System Transponder: Service and Repair Removal ENGINE IMMOBILISER: TRANSPONDER KEY AMPLIFIER: REMOVAL 1. REMOVE LOWER STEERING COLUMN COVER (a) While turning the steering wheel to the right and left, remove the 2 screws. (b) Detach the 2 claws and remove the lower steering column cover. 2. REMOVE TRANSPONDER KEY AMPLIFIER (a) Using a screwdriver, widen the claws attached to the upper bracket by approximately 1 mm (0.0394 in.). (b) Pull out the transponder key amplifier with the claws open. NOTICE: Take care not to apply excessive force to prevent the case from being damaged. Page 5481 Actuator: Service and Repair Removal DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Disconnect the actuator hose. (b) Disconnect the actuator connector. (c) Remove the 4 bolts and actuator. Page 5687 Brake Pedal Assy: Service and Repair Removal BRAKE: BRAKE PEDAL: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY (a) Remove the bolt and air duct. 8. REMOVE PUSH ROD PIN (a) Remove the clip and push rod pin from the brake pedal lever. 9. REMOVE STOP LIGHT SWITCH ASSEMBLY (a) Disconnect the stop light switch connector. (b) Remove the stop light switch See: Lighting and Horns/Brake Light Switch/Service and Repair/Removal. (c) Detach the harness clip. 10. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER (a) Remove the stop light switch mounting adjuster See: Lighting and Horns/Brake Light Switch/Service and Repair/Removal. 11. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Remove the brake pedal return spring. Page 6798 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 1446 Page 5944 Page 1181 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Page 4922 2. REMOVE SHIFT LOCK RELEASE BUTTON (a) Detach the 4 claws and remove the position indicator housing from the floor shift. (b) Detach the 2 claws and remove the button. 3. REMOVE SHIFT LOCK CONTROL ECU (a) Disconnect the shift lock solenoid connector. (b) Detach the 3 claws and remove the ECU. Reassembly A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): REASSEMBLY 1. INSTALL SHIFT LOCK CONTROL ECU Page 4353 NOTICE: For reinstallation, attach a tag or label to the injector shaft. (b) Remove the O-ring from the fuel injector. (c) Detach the 3 clamps and then remove the No. 6 wire harness from the delivery pipe RH. (d) Detach the 3 clamps and then remove the No. 7 wire harness from the delivery pipe LH. Page 6019 Alternator: Overhaul Disassembly 1UR-FE CHARGING: GENERATOR: DISASSEMBLY 1. REMOVE GENERATOR PULLEY SST : 09820-63011 09820-06010 09820-06021 HINT (a) Clamp the generator housing stay in a vise. (b) Install SST 1-A to the pulley shaft. (c) Install SST 1-B to SST 1-A. (d) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque. Torque : 39 Nm (398 kgf-cm, 29 ft-lbf) NOTICE: Check that SST is secured on the rotor shaft. (e) Insert SST 2, and attach the pulley nut to SST 2. (f) To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration. Page 403 Engine Control Module: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Removal 3. DISCONNECT CONNECTOR HOLDER BLOCK (a) Remove the connector holder block cover. (b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in the next step. 4. REMOVE ECM (a) Disconnect the wire harness clamp. (b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration. NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before disconnecting the connectors. Failure to do this may cause the connectors to break. (c) Disconnect the 2 connectors. (d) Remove the 4 bolts and ECM. 5. REMOVE GASKET (a) Peel off the rubber part of the gasket. Page 8578 4. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 5. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 6. REMOVE REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 7. REMOVE REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 8. REMOVE REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 9. REMOVE REAR BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 10. REMOVE REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 11. REMOVE NO. 1 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the rear bumper. 13. REMOVE NO. 2 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. Page 5653 2. INSTALL FRONT SPEED SENSOR LH (a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E). Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) NOTICE: * Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part. * While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip part. * After installing the speed sensor, make sure there is no clearance or foreign matter between the sensor stay part and the knuckle. * Make sure there is no foreign matter attached to the magnetic rotor. 3. INSTALL FRONT SKID CONTROL SENSOR WIRE LH (a) Connect the connector (labeled A). (b) Install the 3 harness clamps (labeled B) with the 3 bolts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamps, do not twist the wire harness. * For clamps with rotation stoppers, make sure the rotation stopper touches the installation position. (c) Install the harness clamp with the bolt (labeled D). Page 8901 Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation Page 7603 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 3410 HINT * o: DTC is memorized. * *1: Only during failure status. Page 3851 (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. Page 7 Accessory Relay: Diagrams Page 3069 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Diagrams Shift Interlock Solenoid: Diagrams Page 7831 Ambient Temperature Sensor / Switch HVAC: Diagrams Page 4625 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Specifications Fuel Pressure: Specifications FUEL PRESSURE Page 270 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Locations Starter Relay: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Locations Steering Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 275 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 8608 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 5. Verify normal USB operation after repair. Page 9054 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 4604 Page 9226 pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel. HINT Tape the screwdriver tip before use. 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window) (a) Using a screwdriver, detach the 2 clips and front upper armrest base panel. HINT Tape the screwdriver tip before use. (b) Disconnect the connectors. 4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Power Window) (a) Remove the 3 screws and power window regulator master switch. 5. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window) (a) Insert a clip remover between the plate and trim. (b) Turn the handle clockwise to remove the handle. Page 3101 Ignition Switch: Service and Repair Installation 1UR-FE STARTING: IGNITION SWITCH: INSTALLATION 1. INSTALL IGNITION SWITCH ASSEMBLY (a) Attach the 2 claws to install the ignition switch to the steering lock. 2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Reassembly 3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly 4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly 5. INSTALL STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation. (b) for Manual Tilt and Manual Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation. (c) for Power Tilt and Power Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Drivetrain - Front Driveshaft Ticking Noise In 4WD Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Front Driveshaft Ticking Noise In 4WD T-SB-0045-10 January 27, 2010 Front Propeller Shaft Parts Label Delaminating - Ticking Noise Service Category Drivetrain Section Drive Shaft/Propeller Shaft Market USA Applicability Introduction Some 2008 - 2010 model year 4WD Sequoia and 2007 - 2010 model year 4WD Tundra vehicles may have a ticking noise present only when in 4WD. Production changes have been made to correct this condition. Follow the procedure in this bulletin to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Repair Procedure 1. Confirm there is a ticking noise only present in 4WD. Page 8891 Entertainment System Control Module: Diagrams Components Control Module: Service and Repair Components JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 5109 Actuator: Service and Repair Removal DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Disconnect the actuator hose. (b) Disconnect the actuator connector. (c) Remove the 4 bolts and actuator. Back Power Window Switch Power Window Switch: Service and Repair Back Power Window Switch Components WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: COMPONENTS Removal WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Using a screwdriver, detach the 2 claws. HINT Page 9050 Page 3377 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 4957 * Make sure the paint marks and pinching portion of each clip are facing the directions shown in the illustration. 5. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/ Trailer Towing System) (a) Coat 2 new O-rings with ATF and install them to the grooves of the transmission oil cooler. (b) Install the oil cooler to the transmission oil thermostat with the 3 bolts. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) (c) Install the 2 No. 1 transmission oil cooler hoses to the transmission oil thermostat. NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the illustration. (d) Connect the 2 No. 1 transmission oil cooler hoses to the transmission. NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the illustration. (e) Temporarily install the transmission oil cooler together with the transmission oil thermostat with bolt C. Temporarily install bolt A and bolt B. Tighten the bolts in alphabetical order. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) (f) Connect the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet hose to the oil cooler tube. NOTICE: * When connecting the hoses to the tube, support the tube by hand and be careful to prevent the tube from being deformed. * Make sure the paint marks and pinching portion of each clip are facing the directions shown in the illustration. (g) Install the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet hose to the transmission oil thermostat. NOTICE: Make sure the paint marks and pinching portion of each clip are facing the directions shown in the illustration. 6. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/o Trailer Towing System) Page 4696 Transmission Speed Sensor: Diagrams Page 5275 (b) Using SST, measure and record the angle of the rear differential flange (B). SST : 09370-50010 3. TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type) HINT When replacing the spider bearing, make sure that the grease fitting assembly hole is facing in the direction shown in the illustration. (a) w/o Bearing Washer: Page 53 (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT The procedures listed below are for the LH side. 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL FRONT DOOR SCUFF PLATE RH (a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT The procedures listed below are for the LH side. Page 8415 2. INSTALL FRONT SEAT ASSEMBLY LH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Installation. 3. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 4904 (d) Using a T30 "TORX" wrench, remove the 3 bolts and column shift. Installation A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL COLUMN SHIFT ASSEMBLY (a) Using a T30 "TORX" wrench, install the column shift with the 3 bolts. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) (b) Connect the connector and attach the harness clamp. (c) Connect the column shift transmission control cable end to the column shift. NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that the ridged side of the cable end is facing upward. 2. ADJUST SHIFT LEVER POSITION See: Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type) Page 3397 HINT The ECM uses the CAN communication system to perform DTC communication instead of the conventional communication line (SIL). CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: SYSTEM DESCRIPTION 1. BRIEF DESCRIPTION (a) The CAN (Controller Area Network) is a serial data communication system for real time application. It is a vehicle multiplex communication system which has a high communication speed (500 kbps, 250 kbps) and the ability to detect malfunctions. (b) By pairing the CANH and CANL bus lines, the CAN performs communication based on differential voltages. (c) Many ECUs (sensors) installed on the vehicle operate by sharing information and communicating with each other. (d) The CAN has 2 resistors of 120 Ohms which are necessary to communicate with the main wire. 2. DEFINITION OF TERMS (a) Main wire (1) The main wire is a wire harness between the 2 termination circuits on the bus (communication line). This is the main bus in the CAN communication system. (b) Branch wire Page 1913 Fluid - A/T: Service and Repair A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT NOTICE: * This transmission requires Toyota Genuine ATF WS. * After servicing the transmission, you must follow the ATF adjustment procedure. * Maintain the vehicle in a horizontal position while adjusting the fluid level. 1. PRELIMINARY PROCEDURES (a) w/ Trailer Towing System (with transmission oil thermostat): (1) Using compressed air, etc., blow dust off the thermostat cap to clean it. (2) Using a screwdriver, push in the shaft of the thermostat. HINT * Distance pushed: 5.5 to 7.0 mm (0.217 to 0.276 in.) * Push the shaft until the screwdriver contacts the step inside the cap. (3) With the shaft of the thermostat pressed, push a pin into a hole in the side of the thermostat cap. Insert the pin until it passes through the hole in the other side of the thermostat cap to fix the shaft in place. HINT Pin diameter: 1.0 to 1.8 mm (0.0394 to 0.0709 in.) 2. BEFORE FILLING TRANSMISSION * When you have replaced the entire transmission, transmission pan, drain plug, valve body and/or torque converter, proceed to the "Transmission Fill" procedures. Page 5181 Axle Shaft Assembly: Component Tests and General Diagnostics Front Drive Shaft Assembly DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): INSPECTION 1. INSPECT FRONT DRIVE SHAFT ASSEMBLY NOTICE: Move the drive shaft while keeping it level. (a) Check if there is excessive play in the outboard joint. (b) Check if the inboard joint shaft slides smoothly in the thrust direction. (c) Check if there is excessive play in the radial direction of the inboard joint shaft. (d) Check the boots for damage. Rear Axle Shaft AXLE: REAR AXLE SHAFT: INSPECTION 1. INSPECT REAR AXLE SHAFT (a) Using a dial indicator, measure the rear axle shaft runout and flange runout. Maximum runout: Shaft runout 1.50 mm (0.0591 in.) Flange runout 0.05 mm (0.00197 in.) (b) If the rear axle shaft or flange is damaged or worn, or if the runout is greater than the maximum, replace the rear axle shaft. Page 6761 JJ1-JL1 Components Tire Pressure Module: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS Page 7641 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 8072 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 6190 Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Crewmax Column Shift Type) Components OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS Removal OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL 1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly Page 6837 Locations Ignition Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 295 Driver Side J/B - Cowl Side Left Page 6672 Diode: Diagrams Diode (Rear Door Courtesy Light) Page 9267 Hood Latch Release Cable: Service and Repair Removal ENGINE HOOD / DOOR: HOOD LOCK CONTROL CABLE ASSEMBLY: REMOVAL 1. REMOVE HOOD LOCK CONTROL CABLE COVER (a) Remove the screw. (b) Remove the cap and nut. (c) Detach the clamp and remove the cable cover. 2. REMOVE HOOD LOCK ASSEMBLY (a) Remove the cap. (b) Remove the 2 bolts and nut. (c) Remove the hood lock. (d) w/ Theft Deterrent System: (1) Disconnect the hood lock control cable. 3. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY (a) Detach the 2 claws. (b) Disconnect the hood lock control cable and remove the hood lock lever. 4. REMOVE HOOD LOCK CONTROL CABLE ASSEMBLY Page 9255 2. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH (a) Using a screwdriver, detach the 2 clips and rear upper door armrest base panel. Then disconnect the connector. HINT Tape the screwdriver tip before use. 3. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Detach the 4 claws and remove the power window regulator switch. 4. REMOVE REAR DOOR FRAME GARNISH LH (a) Detach the 4 clips and remove the rear door frame garnish. 5. REMOVE REAR DOOR ARMREST COVER LH 6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Remove the 2 screws. (b) Using a clip remover, remove the clip. (c) Detach the 9 clips and remove the trim cover. Then disconnect the connector. (d) Disconnect the 2 cables from the inside handle. Page 6913 "Case2" 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 9147 Body Control Module: Locations LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Drivetrain - Rear Differential Growl/Whine While Driving Differential Case: All Technical Service Bulletins Drivetrain - Rear Differential Growl/Whine While Driving T-SB-0297-10 November 2, 2010 Rear Differential Housing Oil Baffle Growl/Whine Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some vehicles may exhibit a growl or whine noise from the rear when the vehicle is in motion. Production changes have been made to prevent this noise. Follow the procedure in the bulletin to address this noise condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 9223 Components Brake Light Switch: Service and Repair Components LIGHTING: STOP LIGHT SWITCH: COMPONENTS Page 6851 Console Box Wire Engine Wire Components Spark Plug: Service and Repair Components 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS Page 6677 Page 8104 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 5024 3. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair 4. REMOVE REAR AXLE SHAFT LH (a) Remove the rear axle shaft LH See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Removal and Replacement/Rear Axle Shaft/Removal. 5. REMOVE REAR AXLE SHAFT RH HINT Use the same procedures described for the LH side. 6. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY (a) Remove the 10 nuts, 10 washers and differential carrier. NOTICE: Be careful not to damage the contact surfaces of the differential carrier and rear axle housing. (b) Remove the gasket. Installation DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): INSTALLATION 1. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY (a) Clean the contact surfaces of the rear differential carrier and the rear axle housing. (b) Install a new rear differential carrier gasket and the differential carrier with the 10 washers and 10 nuts. Torque : 72 Nm (734 kgf-cm, 53 ft-lbf) NOTICE: Be careful not to damage the installation surface. 2. INSTALL REAR AXLE SHAFT LH (a) Install the rear axle shaft LH See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Removal and Replacement/Rear Axle Shaft/Installation. 3. INSTALL REAR AXLE SHAFT RH HINT Use the same procedures described for the LH side. Page 7124 Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch Page 7775 (a) Install the heater radiator unit. (b) Attach the 3 claws to install the heater clamp. (c) Install the plate with the 3 screws. 5. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) (a) Install the damper servo with the 3 screws, as shown in the illustration. (b) Connect the connector. 6. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. Page 2491 Front Crankshaft Seal: Service and Repair Installation 1UR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: INSTALLATION 1. INSTALL FRONT CRANKSHAFT OIL SEAL (a) Apply MP grease to the lip of a new oil seal. (b) Using SST and a hammer, tap in the oil seal to a depth between 0 to 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge. SST : 09223-22010 SST : 09506-35010 NOTICE: * Keep the lip free from foreign matter. * Do not tap the oil seal at an angle. 2. INSTALL CRANKSHAFT TIMING GEAR KEY (a) Install the crankshaft timing gear key. 3. INSTALL CRANKSHAFT PULLEY See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Installation 4. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY See: Engine Lubrication/Oil Cooler/Service and Repair/Removal and Replacement/Installation 5. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See: Engine Lubrication/Oil Cooler/Service and Repair/Removal and Replacement/Installation 6. INSTALL WATER BY-PASS PIPE (w/ Oil Cooler) See: Water Pump/Service and Repair/Installation 7. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY See: Engine Lubrication/Oil Pressure Sender/Service and Repair/Installation 8. CONNECT COOLER COMPRESSOR ASSEMBLY See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Installation 9. CONNECT FRONT STABILIZER BAR (a) Connect the stabilizer bar and install the 2 stabilizer bushes and 2 stabilizer brackets with the 4 bolts. Torque : 69 Nm (704 kgf-cm, 51 ft-lbf) Page 6790 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2808 Engine Control Module: Locations Engine Compartment Page 9057 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Wire and Wire In Engine Compartment Multiple Junction Connector: Locations Wire and Wire In Engine Compartment AB1-RA3 Page 6987 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 6089 Page 1698 Standard vehicle height (unloaded vehicle): for Regular Cab of Long Deck Standard vehicle height (unloaded vehicle): for Double Cab of Standard Deck Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5496 Shift Interlock Control Module: Diagrams Components Ignition Switch: Service and Repair Components 1UR-FE STARTING: IGNITION SWITCH: COMPONENTS Page 9116 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 3079 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Components Throttle Body: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: COMPONENTS Components Parking Brake Cable: Service and Repair Components PARKING BRAKE: PARKING BRAKE CABLE: COMPONENTS Power Steering Oil Pressure Sensor Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor Page 2035 J/B No.5 - Instrument Panel Center Page 4506 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Components Seat Position Sensor: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: COMPONENTS Page 7637 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 5688 (b) Remove the bolt from the No. 3 brake pedal bracket. (c) Remove the bolt, nut and No. 3 brake pedal bracket from the brake pedal support. (d) Remove the 4 nuts and brake pedal support. 12. REMOVE BRAKE PEDAL PAD (a) Remove the brake pedal pad. Page 1730 (m)Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (o) Stop the engine. (p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Standard fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or higher (q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and carefully remove SST and the fuel tube connector to prevent gasoline from spraying. (s) Reconnect the fuel tube (fuel tube connector). (t) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. Locations Power Seat Control Module: Locations Seat (Separate Seat) Page 7595 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: MIL Circuit - MIL Circuit DESCRIPTION The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunction detections by the ECM. When the ignition switch is turned to ON, power is supplied to the MIL circuit, and the ECM provides the circuit ground which illuminates the MIL. The MIL operation can be checked visually: When the ignition switch is first turned to ON, the MIL should be illuminated and should then turn off when the engine is started. If the MIL remains illuminated or is not illuminated, conduct the following troubleshooting procedure using the Techstream. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. CHECK THAT MIL IS ILLUMINATED (a) Perform troubleshooting in accordance with the table below. Result B -- CHECK THAT MIL IS ILLUMINATED A -- Continue to next step. 2. CHECK WHETHER MIL TURNS OFF (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. (c) Turn the Techstream on. Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 6312 AB1-DF1 Page 5202 HINT Align the 2 oil drain holes. (b) Temporarily install a washer and nut to 5 new hub bolts as shown in the illustration. (c) Install the hub bolts by tightening each nut. (d) Removed the washer and nut from each hub bolt. 2. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY (a) Position the parking brake plate on a new rear axle hub and bearing. NOTICE: Make sure to securely fit the bearing to the parking brake plate. (b) Using 2 socket wrenches and a press, press in the 4 housing bolts. 3. INSTALL REAR AXLE SHAFT (a) Install the washer and a new retainer to the axle hub as shown in the illustration. Page 8123 Seat Occupant Classification Module - Air Bag: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 2478 (a) Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration. (b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. HINT Be sure to arrange the removed parts for each installation position separately. NOTICE: * Be careful not to drop washers into the cylinder head. * Head warpage or cracking could result from removing bolts in an incorrect order. 7. REMOVE CYLINDER HEAD GASKET LH Installation 1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 1): INSTALLATION 1. INSPECT CYLINDER HEAD SET BOLT See: Testing and Inspection/Engine Unit 2. INSPECT CYLINDER HEAD SUB-ASSEMBLY LH See: Cylinder Head Assembly/Testing and Inspection 3. INSTALL CYLINDER HEAD GASKET LH (a) Check the piston protrusions for each cylinder. (1) Clean the cylinder block with solvent. (2) Set the piston of the cylinder to be measured to slightly ATDC. (b) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward. NOTICE: * Be careful of the installation direction. * Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket. 4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH (a) Place the cylinder head on the cylinder block. Page 6570 Auxiliary Power Outlet Switch: Service and Repair Removal OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INVERTER MAIN SWITCH (a) Detach the 2 claws and remove the main switch. Page 4213 Page 1527 Power Steering Pressure Switch: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT POWER STEERING OIL PRESSURE SWITCH (a) Check the oil pressure switch. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch on. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering pressure. (5) Start the engine. (6) Operate the steering wheel while idling, and read the value on the Techstream. Standard: (7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Inspect the power steering system See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Page 4503 Camshaft Position Sensor: Diagrams Page 3504 NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step. 6. CONNECT CONNECTOR (a) Reconnect the J94 No. 1 junction connector connector. (b) Reconnect the J113 No. 2 junction connector connector. NEXT -- Continue to next step. 7. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU) (a) Disconnect the J84 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU) OK -Continue to next step. 8. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - MAIN BODY ECU) (a) Disconnect the J96 No. 1 junction connector connector. Page 3393 (b) Use a repair wire to check the connector if it is impossible to check resistance from the rear of the connector. Page 7429 Tire Pressure Module: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL NOTICE: * It is necessary to perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. * When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU using the intelligent tester or Techstream and write them down before removal. 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the ECU connector. (b) Remove the 2 nuts and ECU. Diagram Information and Instructions Relay Box: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 5955 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Body - Bumper Component Repair Rear Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: BUMPER COMPONENT REPAIR SECTION: EXTERIOR BULLETIN # 172 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2009 While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinforcements there is no way to certify that a repaired part will function as originally intended under all future operating conditions and subsequent collisions. Original Equipment bumper components comply with Federal Motor Vehicle Safety Standards established under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is recommended to replace damaged bumper impact energy absorbers and reinforcements with genuine new original equipment replacement parts only. For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair & Refinish Training. Visit www.crrtraining.com for training information. Components Vacuum Brake Booster: Service and Repair Components BRAKE: BRAKE BOOSTER: COMPONENTS Locations Central Control Module: Locations NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION m Page 2809 Engine Control Module: Diagrams Page 1003 Fuel Gauge Sender: Service and Repair Fuel Sending Unit Cover Fuel Sending Unit Upper Cover Installation Introduction A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010 MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair Manual by providing the installation procedures and part number details for this component. Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit Upper Cover. Production Change Information This information applies to vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information (Continued) Parts Information Warranty Information Page 6205 (a) Attach the claw to install the power outlet socket. 3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) Components OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS Page 6946 Engine Room R/B And Engine Room J/B Inner Circuit Page 3427 HINT * *1: w/ Power Steering ECU * *2: w/ 4WD * *3: w/ Bus Buffer ECU Short in CAN Bus Lines CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short in CAN Bus Lines - Short in CAN Bus Lines DESCRIPTION There may be a short circuit between the CAN bus lines when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ohms. HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU WIRING DIAGRAM Page 1996 Components Variable Valve Timing Actuator Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS Page 6060 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 6838 Page 1472 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. Page 781 Brake Fluid Pressure Sensor/Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Yaw Rate Sensor: Service and Repair Components BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS Page 5830 Traction Control Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 1290 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 919 Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 2782 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Components Seat Position Sensor: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: COMPONENTS Page 722 Power Seat Switch: Service and Repair Front Power Seat Lumbar Switch (for Manual Seat) Components SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): COMPONENTS Locations Shift Interlock Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 8828 (a) Using a screwdriver, detach the 4 clips and claw. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 5. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Using a screwdriver, detach the 4 clips and claw. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY LH (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. Page 7964 Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) (2) Tie the curtain shield airbag to the tire with several wire harnesses. CAUTION: Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the curtain shield airbag may become loose due to the shock when the airbag is deployed. NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (e) Install SST. (1) After connecting SST each other, connect them to the curtain shield airbag. SST : 09082-00802 09082-10801 09082-40800 (f) Place the tires. NOTICE: Do not place the deployment direction of the curtain shield airbag facing the ground. (1) Place at least 2 tires under the tire which the curtain shield airbag is tied to. (2) Place at least 2 tires over the tire which the curtain shield airbag is tied to. The top tire should have the disc wheel installed. NOTICE: * Do not place SST connector under the tire because it could be damaged. * As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. * As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (3) Tie the tires together with 2 wire harnesses. Page 6247 Fuse Block Location - Under The Instrument Panel Fuse Location - Under The Instrument Panel Page 6023 Torque : 2.3 Nm (23 kgf-cm, 20 in-lbf) 2. INSTALL GENERATOR ROTOR ASSEMBLY (a) Place the drive end frame on the pulley. (b) Install the rotor to the drive end frame. 3. INSTALL GENERATOR COIL ASSEMBLY (a) Place the generator washer on the rotor. (b) Using SST and a press, slowly press in the coil assembly. SST : 09285-76010 (c) Install the 4 bolts. Page 6464 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 2653 Engine Temperature Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Partially immerse the sensor in water and warm up the water. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the engine coolant temperature sensor. NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. HINT If the result is as specified, do not replace the engine coolant temperature sensor. Page 8811 Removal AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE NO. 1 BOX SPEAKER ASSEMBLY Audio System - Satellite Radio Inop. Until Key Is Cycled Radio Receiver: All Technical Service Bulletins Audio System - Satellite Radio Inop. Until Key Is Cycled T-SB-0271-09 Rev1 August 11, 2009 XM Satellite Radio Inoperative Until Ignition Key Is Cycled Service Category Audio/Visual/Telematics Section Audio/Video Market USA Applicability March 30, 2010 Rev1: TSB REVISION NOTICE ^ Applicability has been updated to include additional 2010 - 2011 model year Toyota vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Some vehicles equipped with a PPO/DIO accessory XM Satellite Radio Receiver (P/N 86180-0W030 or 86180-0W031) may exhibit one or more of the following conditions: ^ XM Satellite Radio becomes non-operational or locked while in use. ^ Sound output becomes sporadic or non-existent. When either of these conditions occur cycling the ignition from "ON"-"OFF"-"ON" restores normal operation. Improved XM Satellite Radio Receiver exchange units are available to correct this condition. NOTE Page 7676 Compressor Clutch Relay: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 3580 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Page 736 (f) If the result is not as specified, replace the switch. 4. INSPECT SEAT HEATER SWITCH RH (w/ Climate Control Seat System) (a) Measure the resistance according to the value(s) in the table below. Standard Resistance (for Heater): Standard Resistance (for Blower): HINT As the dial is being turned, the resistance changes gradually. (b) If the result is not as specified, replace the switch. (c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. OK: (d) If the result is not as specified, replace the switch. (e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. OK: Page 6886 Power Distribution Module: Service and Repair Removal OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 6. REMOVE VOLTAGE INVERTER ASSEMBLY (a) Remove the 2 bolts. (b) Disconnect the voltage inverter connector and removal the voltage inverter. Page 6612 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 3689 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 5221 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 Components Tire Pressure Monitor Receiver / Transponder: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS Air Switching Valve (for Bank 1) Air Injection Control Valve: Service and Repair Air Switching Valve (for Bank 1) Components 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): COMPONENTS Removal 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): REMOVAL 1. DISCONNECT NO. 2 AIR HOSE (a) Disconnect the No. 2 air hose and connector. 2. REMOVE AIR SWITCHING VALVE ASSEMBLY (a) Remove the bolt and disconnect the wire harness clamp bracket. Page 176 Page 5212 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 5078 (a) Using a chisel and hammer, stake the nut. 42. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end. SST : 09608-32010 (b) Coat the lip of the oil seal with MP grease. Standard oil seal depth: -0.45 to 0.45 mm (-0.0177 to 0.0177 in.) 43. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY (a) Install a new snap ring onto the side gear inter shaft. (b) Using a plastic-faced hammer, install the side gear inter shaft onto the differential case. (c) Check that there is 2 to 3 mm (0.0788 to 0.118 in.) of play in the axial direction. (d) Check that the side gear inter shaft does not come out when trying to pull it out by hand. 44. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and bearing retainer. Components Power Distribution Module: Service and Repair Components OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. Page 8272 (a) Pass the seat belt through the seatback hole. 3. INSTALL REAR SEAT REAR CUSHION MOULDING RH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 4. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 5. INSTALL REAR SEAT ASSEMBLY LH (a) Install the seat with the 4 bolts. Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) 6. CONNECT REAR SEAT INNER BELT ASSEMBLY Page 9384 6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be used in their place 7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts (see Figures 8 and 9). Page 6940 J/B No.3 - Instrument Panel Right Page 4735 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 7489 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Install the receiver with the bolt. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the receiver connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 3908 Page 2109 (d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. (e) Check if any DTCs have been stored. Note down any DTCs. (f) Clear DTCs See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. (g) Check if the MIL goes off. OK: MIL goes off. NG -- CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) OK -- REPAIR CIRCUITS INDICATED BY OUTPUT DTCS See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Engine Control System - SFI System 3. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) (a) Disconnect the ECM connector. (b) Turn the ignition switch to ON. (c) Check that the MIL is not illuminated. OK: MIL is not illuminated. NG -- CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) OK -- REPLACE ECM See: Powertrain Management/Computers and Control Systems/Engine Control Module/Service and Repair/Removal 4. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) Page 7554 Air Door Actuator / Motor: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 3638 Power Steering Pressure Switch: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: REMOVAL 1. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DRAIN POWER STEERING FLUID 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the power steering oil pressure switch connector. (b) Remove the power steering oil pressure switch. (c) Remove the O-ring. Page 4811 Actuator: Service and Repair Removal DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Disconnect the actuator hose. (b) Disconnect the actuator connector. (c) Remove the 4 bolts and actuator. Page 3813 Knock Sensor: Diagrams Page 9366 12. Torque the NEW nuts to the specified torque range on the No.2 mounts. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) 13. Reinstall the body plugs for the cab mount bolt holes and then restore the carpet to its original position. 14. Test drive vehicle to confirm the condition has been improved. Page 3925 Variable Valve Timing Actuator Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION 1. INSTALL VVT SENSOR (a) Install the 4 sensors with the 4 bolts. Page 4538 Page 4522 Page 1308 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 6078 If the customer has experienced a RES malfunction above -22 F (-30 C) proceed with diagnosis referencing the applicable troubleshooting guide in the Technical Information System (TIS) Accessory tab Accessory Diagnostic Guide: For 2007 Camry, Camry HV; Tundra, and 2006 - 2007 RAV4: Refer also to TSB T-SB-0070-08, "Remote Engine Starter (RES) Cold Temperature Operation". Page 8361 Impact Sensor: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Testing and Inspection Evaporative Emission Control Canister: Testing and Inspection 1UR-FE EMISSION CONTROL: CANISTER: INSPECTION 1. INSPECT CANISTER ASSEMBLY (a) Visually check the canister assembly for cracks or damage. (b) If cracks or damage are found, replace the canister assembly. (c) Check for the canister operation. (1) With the purge port closed, blow 1.67 kPa (20 gf/cm2, 0.24 psi) of air into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the canister assembly. (2) With the vent port closed, blow 1.06 kPa (10 gf/cm2, 0.15 psi) of air inlet port, and check that air flows from the purge port. (3) If the result is not as specified, replace the canister assembly. (d) Check for air leak. Page 8300 Front Seat Belt Extender Applications Page 1428 between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 9. INSTALL FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): COMPONENTS Page 8626 (a) Attach the 2 claws to install the adapter. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 7. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 9. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 10. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 11. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 12. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Double Cab: Install the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (b) for Regular Cab: Install the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (c) for CrewMax: Install the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 3703 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 6990 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 6683 Engine Room R/B, J/B - Engine Compartment Left Page 4131 Page 3926 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 3419 INSPECTION PROCEDURE HINT * Perform the following inspection for the ECUs (sensors) which are not displayed on the Techstream. If a malfunction cannot be identified, perform the following inspections for the ECUs (sensors) connected to the CAN communication system. * Do not remove the combination meter and ECM, as they are the end parts of the circuit. If removed, CAN communication will not be possible. * The open circuit confirmation of the combination meter, ECM and main wire is performed in the CHECK CAN BUS LINE procedure of "HOW TO PROCEED WITH TROUBLESHOOTING". This inspection only has procedures for checking for an open circuit on one side of the CAN branch wire. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. Components Evaporator Temperature Sensor / Switch: Service and Repair Components AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: COMPONENTS Page 8694 Integrated Accessory Switch Assembly: Service and Repair Installation METER: DRIVE MONITOR SWITCH: INSTALLATION 1. INSTALL DRIVE MONITOR SWITCH (a) Attach the 2 claws to install the monitor switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Center Airbag Sensor Assembly (for Column Shift Type) Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Column Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): COMPONENTS Page 7920 Air Bag: Testing and Inspection Curtain Shield Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: ON-VEHICLE INSPECTION 1. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the curtain shield airbag installed on the vehicle, perform a visual check. If any of the defects mentioned below are present, replace the curtain shield airbag with a new one: Cuts, minute cracks or marked discoloration on the curtain shield airbag. 2. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the curtain shield airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the curtain shield airbag with a new one: * Cuts, minute cracks or marked discoloration on the curtain shield airbag. * Cracks or other damage to the connectors. CAUTION: For removal and installation procedures of the curtain shield airbag, be sure to follow the correct procedure. Locations Ignition Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 49 Double Cab)/Removal 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 6. REMOVE REAR DOOR SCUFF PLATE RH (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT The procedures listed below are for the LH side. 7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH 3. INSTALL REAR DOOR SCUFF PLATE RH (a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT The procedures listed below are for the LH side. 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Page 4579 Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 472 Page 2794 ^ 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 786 Braking Sensor/Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Page 5054 09952-04010 09953-04020 09954-04010 09955-04011 09957-04010 09958-04011 (b) Remove the snap ring from the side gear inter shaft. 5. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT (a) Using SST and a hammer, unstake the nut. SST : 09930-00010 (b) Using SST to hold the companion, remove the nut. SST : 09330-00021 09330-00030 6. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, remove the companion flange from the differential carrier. SST : 09950-30012 09951-03010 09953-03010 Page 4787 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 4038 Air Injection Pump: Testing and Inspection 1UR-FE EMISSION CONTROL: AIR PUMP: ON-VEHICLE INSPECTION 1. INSPECT AIR PUMP ASSEMBLY (a) Start the engine and warm it up. (b) Turn the ignition switch off. (c) Connect the 400 A probe of an ammeter to the (+) wire of the air pump. (d) Connect the Techstream to the DLC3. (e) Turn the ignition switch to ON and turn the Techstream ON. (f) Enter the following menus: Powertrain / Engine and ECT / Utility / Air Injection Check / Manual Mode / AIR PUMP 1: ON, ASV1: OPEN, AIR PUMP 2: ON, ASV2: OPEN. HINT When Manual Mode is selected, the Techstream initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected. (g) Measure the current while the air pump is turning. Standard Current: (h) If the result is not as specified, replace the air pump. (i) Turn the ignition switch to OFF. NOTICE: * This Air Injection Check only allows technicians to operate the AIR system for a maximum of 5 seconds. * Furthermore, the check can only be performed up to 4 times per trip. If the test is repeated, intervals of at least 30 seconds are required between checks. * While AIR system operation using the Techstream is prohibited, the Techstream display indicates the prohibition (WAIT or ERROR). * If an ERROR is displayed on the Techstream during the test, stop the engine for 10 minutes, and then try again. * Performing the Air Injection Check repeatedly may cause damage to the AIR system. If necessary, leave an interval of several minutes between Air Injection Check operations to prevent the system from overheating. * When performing the Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running. * Turn the ignition switch off when the Air Injection Check operation finishes. Page 1062 (b) Disconnect the connector and remove the courtesy switch. Installation LIGHTING: FRONT DOOR COURTESY SWITCH: INSTALLATION HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL FRONT DOOR COURTESY SWITCH (a) Connect the connector. (b) Install the courtesy switch with the bolt. Page 5933 Yaw Rate Sensor: Service and Repair Installation BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION 1. INSTALL YAW RATE SENSOR (a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of the sensor bracket. (b) Install the yaw rate sensor with the 2 nuts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * Make sure that the sensor is oriented correctly. * If the sensor is dropped, replace it. * Securely connect the connector. * When installing the sensor, make sure to avoid impacts to the sensor. 2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation 3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning. 6. CHECK YAW RATE SENSOR SIGNAL (a) Check the yaw rate sensor signal See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 3977 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Components Seat Memory Switch: Service and Repair Components SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): COMPONENTS Page 2156 Tire Pressure Sensor: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL 1. REMOVE TIRE 2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Remove the valve core and cap, and release the air from the tire. (b) After ensuring that a sufficient amount of air has been released, remove the nut and washer that is used to secure the tire pressure warning valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire. HINT Keep the removed cap, valve core, nut and washer. (c) Disengage the bead using the shoe of a tire remover. NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due to interference between the sensor and tire bead. (d) Remove the bead on the upper side. (e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on the lower side. HINT * The grommet is a non-reusable part. * Check that there are no cracks or damage on the grommet. If any damage is found, replace the washer and nut. Page 4577 Page 4956 Transmission Cooler: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: OIL COOLER: INSTALLATION 1. INSTALL OIL COOLER TUBE (w/ Trailer Towing System) (a) Temporarily install the oil cooler tube to the engine with bolt A. Install bolt B and tighten it to the specified torque. Then tighten bolt A to the specified torque. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) 2. INSTALL NO. 2 OIL COOLER TUBE (w/ Trailer Towing System) (a) Install the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose to the No. 2 oil cooler tube. NOTICE: Make sure the paint marks and pinching portion of each clip are facing the directions shown in the illustration. (b) Install the No. 2 oil cooler tube together with the 2 oil cooler hoses with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose to the cooler condenser. NOTICE: * Make sure the paint marks are facing the directions shown in the illustration. * Make sure the pinching portion of each clip is not in the hatched areas shown in the illustration. 3. INSTALL COOLER CONDENSER ASSEMBLY (AIR COOLED OIL COOLER) (w/ Trailer Towing System) (a) Install the cooler condenser See: Heating and Air Conditioning/Condenser HVAC/Service and Repair/Installation. 4. INSTALL OIL COOLER ACCESSORY ASSEMBLY (w/ Trailer Towing System) (a) Install the oil cooler accessory assembly to the oil cooler tube, and then pass the 2 hoses through the No. 1 flexible hose clamp and close the clamp as shown in the illustration. (b) Connect the 2 hoses to the No. 2 oil cooler tube. NOTICE: * When connecting the hoses to the tube, support the tube by hand and be careful to prevent the tube from being deformed. Page 2556 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 6943 J/B No.6 Assembly - Instrument Panel Center Page 9051 Trailer Lamps: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Air Conditioning System (for Automatic Air Conditioning System) Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 4196 Page 2511 Variable Valve Timing Actuator Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION 1. INSTALL VVT SENSOR (a) Install the 4 sensors with the 4 bolts. Page 1190 Manifold Pressure/Vacuum Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Disconnect the manifold absolute pressure sensor connector. (b) Remove the screw and manifold absolute pressure sensor. (c) Remove the O-ring from the manifold absolute pressure sensor. Page 5034 7. REMOVE REAR DRIVE PINION NUT (a) Using SST and a hammer, unstake the nut. SST : 09930-00010 (b) Using SST to hold the companion flange, remove the nut. SST : 09330-00021 09330-00030 8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, remove the companion flange. SST : 09950-30012 09951-03010 09953-03010 09954-03010 09956-03030 SST : 09955-03050 9. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR (a) Using SST, a steel plate and press, press out the dust deflector. Page 3200 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 5035 SST : 09950-00020 NOTICE: Do not drop the companion flange. 10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal. SST : 09308-10010 11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST, remove the bearing (inner race). SST : 09556-22010 (b) Remove the bearing spacer. 13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK (a) Remove the 2 bolts and 2 nut locks. 14. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY Page 3027 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 5713 Brake Fluid: Testing and Inspection BRAKE: BRAKE FLUID: ON-VEHICLE INSPECTION 1. CHECK BRAKE FLUID LEVEL IN RESERVOIR (a) Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 HINT The brake fluid level must always be adjust to the MAX line. Page 1762 (4) Remove the 2 bolts and disconnect the water by-pass pipe. (5) Remove the 4 bolts and 4 ignition coils. 4. REMOVE SPARK PLUG (a) Using a 16 mm plug wrench, remove the 8 spark plugs. Page 6927 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 9394 7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts. 8. With the cab still raised install the new No.3 cab mounts. 9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to specification. Torque: 61 N*m (622 kgf*cm, 45 ft*lbf) Page 6489 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 8251 (a) Align the vehicle's claws with the seat belt retractor positioning holes. (b) Install the seat belt with the 2 bolts. HINT First install the bolt A, and then install bolt B. for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Connect the pretensioner connector as shown in the illustration. (d) Install the shoulder anchor to the shoulder belt anchor adjuster with the nut. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 3. INSTALL LOWER CENTER PILLAR GARNISH Page 2208 No further tightening is required once the nut is tightened with the specified torque. 2. INSTALL WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 3. INSPECT TIRE (a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics. 4. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Testing and Inspection/Programming and Relearning/Registration. 5. PERFORM INITIALIZATION (a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 6. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Page 8060 Impact Sensor: Diagrams Front Airbag Sensor Locations Transmission Speed Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 7193 HINT Tape the screwdriver tip before use. 4. REMOVE VANE PUMP SHAFT SUB-ASSEMBLY WITH PULLEY (a) Using 2 screwdrivers, remove the snap ring from the vane pump shaft. (b) Remove the vane pump shaft sub-assembly with pulley. NOTICE: Be careful not to drop or damage the vane pump shaft sub-assembly with pulley. If it is damaged, replace the vane pump assembly. 5. REMOVE VANE PUMP ROTOR (a) Remove the 10 vane plates. NOTICE: Take care not to drop the vane plate. (b) Remove the vane pump rotor. 6. REMOVE VANE PUMP CAM RING (a) Remove the cam ring from the front housing. 7. REMOVE VANE PUMP FRONT SIDE PLATE Page 6504 Driver Side J/B Inner Circuit Page 5150 Replacement DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER OIL SEAL (for 4WD): REPLACEMENT 1. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair 2. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Remove the differential carrier See: Differential Carrier/Service and Repair/Removal and Replacement/Front Differential Carrier Assembly/Removal. 3. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Disassembly Page 9005 Trailer Connector: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 6061 Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 8280 (d) for RH Side: Detach the 3 clips and remove the lower quarter trim panel. 7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 8. REMOVE REAR SEAT OUTER BELT ASSEMBLY (a) Remove the nut and disconnect the seat belt's shoulder anchor. (b) Remove the 2 bolts and seat belt. 9. REMOVE REAR SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Remove the 2 bolts and adjuster. Installation SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): INSTALLATION HINT Page 5502 Control Module: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 8563 Parking Assist Control Module: Service and Repair Removal PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE CLEARANCE WARNING ECU WITH BRACKET (a) Disconnect the ECU connectors and detach the harness clamp. NOTICE: Do not apply excessive force to the wire harnesses. (b) Remove the bolt, nut and ECU with bracket. 8. REMOVE CLEARANCE WARNING ECU ASSEMBLY (a) Remove the 2 nuts and clearance warning ECU from the bracket. NOTICE: * Avoid any impact to the clearance warning ECU. * Do not drop the ECU. If it is dropped, replace it with a new one. Page 2770 ^ 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 6665 Auxiliary Power Outlet Switch: Service and Repair Removal OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INVERTER MAIN SWITCH (a) Detach the 2 claws and remove the main switch. Components Alarm System Transponder: Service and Repair Components ENGINE IMMOBILISER: TRANSPONDER KEY AMPLIFIER: COMPONENTS Page 277 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 6374 Page 818 Traction Control Switch: Testing and Inspection BRAKE CONTROL: VSC OFF SWITCH: INSPECTION 1. INSPECT VSC OFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the VSC OFF switch. Removal and Replacement Drive/Propeller Shaft: Removal and Replacement Components PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): COMPONENTS Page 175 Page 3127 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 6036 Page 6643 Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL 1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 2. REMOVE CONSOLE BOX BEZEL Page 7824 Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Check Mode Procedure. Page 2510 Variable Valve Timing Actuator Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE VVT SENSOR (a) Disconnect the 4 sensor connectors. (b) Remove the 4 bolts and 4 sensors. Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Components Spark Plug: Service and Repair Components 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS SHIFT LEVER ASSEMBLY (for Column Shift Type) Shifter A/T: Adjustments SHIFT LEVER ASSEMBLY (for Column Shift Type) A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When moving the shift lever from N to other positions, check that the lever can be moved smoothly and accurately to each position and that the position indicator comes on in accordance with the shift lever position. If the indicator and shift lever position do not match, carry out the following adjustment procedures. 2. ADJUST SHIFT LEVER POSITION (a) Move the shift lever to N. (b) Fold back the transmission control cable adjust case cover. Then while sliding the slider toward the cable end side, press out the lock piece from the back side to release the lock. (c) Check that the spring of the adjust case is applying enough tension to the shift control cable. Then press in the lock piece to set the lock. NOTICE: * Use your hand to push in the lock piece. Do not use any tools. * Securely push in the lock piece so that the protrusion of the slider is above the lock piece. (d) Return the cover of the adjust case to its original position. (e) Inspect the shift lever operation after the adjustment. Page 7062 Standard steering axis inclination (unloaded vehicle): for Double Cab of Long Deck Components Traction Control Switch: Service and Repair Components BRAKE CONTROL: VSC OFF SWITCH: COMPONENTS Page 2190 (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Occupant Classification System Air Bag Control Module: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 4356 (a) Install the 2 delivery pipe spacers and 4 insulators to the cylinder head RH. (b) Install the delivery pipe (with injectors) to the cylinder head RH. (c) Install the 2 bolts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) NOTICE: Make sure that the part of the injector labeled B is between the parts of the delivery pipe labeled A. (d) Connect the No. 6 wire harness connector. 4. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (a) Connect the No. 1 fuel pipe to the fuel delivery pipe LH See: Service Precautions. 5. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Connect the fuel tube to the delivery pipe LH See: Service Precautions. (b) Connect the fuel tube to the delivery pipe RH See: Service Precautions. 6. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY (a) Connect the No. 2 fuel tube to the fuel pressure regulator See: Service Precautions. Locations Shift Solenoid: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 6067 Ignition Switch: Testing and Inspection 1UR-FE STARTING: IGNITION SWITCH: INSPECTION 1. INSPECT IGNITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the ignition switch assembly. Page 2287 Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the Techstream to the DLC3. (b) Start the engine and turn the tester ON. (c) Warm up the engine. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear (Bank 1) or Control the VVT Linear (Bank 2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2). (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK: (f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear. HINT * Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of bank 1 (Control range: Between -128 to 127%). * Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves of bank 2 (Control range: Between -128 to 127%). * Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range: ON/OFF). * Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range: ON/OFF). * Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of bank 1 (Control range: Between -128 to 127%). * Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of bank 2 (Control range: Between -128 to 127%). Page 7777 (1) Insert the pin into the plate groove. (2) Attach the claw to install the main plate. (3) Install the 2 screws. (c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the damper servo. (d) Install the 4 screws and connect the 2 connectors. 10. INSTALL AIR DUCT Page 4016 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DISCONNECT NO. 3 VENTILATION HOSE (a) Disconnect the No. 3 ventilation hose. 4. DISCONNECT NO. 1 AIR HOSE (a) Disconnect the No. 1 air hose. 5. REMOVE AIR SWITCHING VALVE ASSEMBLY (a) Disconnect the connector and clamp. (b) Remove the bolt and disconnect the wire harness clamp bracket. (c) Remove the 2 bolts. (d) Remove the 3 bolts, air switching valve and gasket. NOTICE: Be careful not to damage the installation surface of the gaskets. Installation 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): INSTALLATION 1. INSTALL AIR SWITCHING VALVE ASSEMBLY Page 1390 Impact Sensor: Service and Repair Front Airbag Sensor Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 3527 NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG SENSOR (CANH, CANL) OK -- REPLACE CENTER AIRBAG SENSOR 19. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) OK -- Continue to next step. 20. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - BUS BUFFER ECU) NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (BUS BUFFER ECU) OK -- Continue to next step. 21. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU) Page 8109 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 7703 Removal AIR CONDITIONING: AIR CONDITIONING PANEL (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Page 1301 Symbols Used Within Diagrams Symbols Used Within Diagrams Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6499 J/B No.6 Assembly - Instrument Panel Center Page 6894 Power Distribution Relay: Testing and Inspection ACC Relay 1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAIN BODY ECU (ACC RELAY) (a) Measure the resistance of the ACC relay circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the main body ECU. Page 4053 Canister Purge Control Valve: Service and Repair Removal 1UR-FE EMISSION CONTROL: PURGE VALVE: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. DISCONNECT PURGE LINE HOSE (a) Disconnect the 2 purge line hoses. 3. REMOVE PURGE VSV (a) Disconnect the connector. (b) Remove the bolt and purge VSV. Page 4310 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 Axle Nut: Specifications FRONT AXLE HUB NUT LH (for 4WD) Using a 39 mm socket wrench, install the hub nut. Torque.................................................................................................................................................. ...............................338 Nm (3446 kgf-cm, 249 ft-lbf) Page 7286 NOTICE: Be careful not to damage the No. 2 steering rack boot. 6. REMOVE NO. 2 STEERING RACK BOOT 7. REMOVE NO. 1 STEERING RACK BOOT 8. REMOVE STEERING RACK END SUB-ASSEMBLY (a) Using a screwdriver and hammer, stake back the washer. NOTICE: Do not strike the steering rack. (b) Using a wrench, hold the steering rack (LH side). (c) Using SST, remove the steering rack end (LH side) from the power steering rack. SST : 09922-10010 NOTICE: Rotate SST in the direction shown in the illustration. (d) Using SST, remove the steering rack end (RH side) from the power steering rack. SST : 09922-10010 NOTICE: Rotate SST in the direction shown in the illustration. (e) Remove the 2 claw washers. 9. REMOVE STEERING GEAR RACK GUIDE (a) Using SST, remove the steering rack guide spring cap nut. SST : 09922-10010 NOTICE: Rotate SST in the direction shown in the illustration. Page 1397 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Page 9292 Page 4346 Fuel Injector: Testing and Inspection 1UR-FE FUEL: FUEL INJECTOR: INSPECTION 1. INSPECT FUEL INJECTOR ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the injector assembly. (c) Inspect the injection volume. CAUTION: This test involves high-pressure fuel and electricity. Take all precautions regarding safe handling of both the fuel and the electricity. Perform this test in a safe area, and avoid any sparks or flames. Do not smoke. (1) Remove the fuel pipe clamp. (2) Disconnect the fuel tube. (3) Connect SST to the fuel pipe (the vehicle side). Page 2318 (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. (c) Install the chain tensioner with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Remove the hexagon wrench from the chain tensioner. 8. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH See: Camshaft (for Bank 1)/Installation 9. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH See: Camshaft (for Bank 1)/Installation 10. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH See: Camshaft (for Bank 1)/Installation 11. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH See: Camshaft (for Bank 1)/Installation 12. TIGHTEN CAMSHAFT TIMING GEAR (a) LH: (1) Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing gear with the bolt. Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf) (2) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear with the bolt. Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf) Page 2750 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 5031 Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf) (f) Tighten the D and E bolts. Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf) (g) Connect the automatic disconnecting differential actuator hose. (h) Connect the automatic disconnecting differential actuator connector. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (a) Install the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Removal and Replacement/Front Drive Shaft Assembly/Installation. 3. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT Use the same procedure as the LH side. 4. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (a) Install the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation. 5. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair 6. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 7. INSTALL FRONT WHEEL (a) Install the front wheels. for aluminum wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for steel wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 8. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and Inspection/Component Tests and General Diagnostics/Touch Select 2-4 and High-Low System. Page 6703 Page 8080 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Page 7801 Refrigerant Pressure Sensor / Switch: Service and Repair Installation AIR CONDITIONING: PRESSURE SWITCH: INSTALLATION 1. INSTALL PRESSURE SWITCH (a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pressure switch. Compressor oil: ND-OIL 8 or equivalent (b) Install the O-ring on the pressure switch. (c) Install the switch. Torque : 10.8 Nm (110 kgf-cm, 8 ft-lbf) (d) Connect the connector. 2. CHARGE REFRIGERANT See: Service and Repair 3. WARM UP ENGINE See: Service and Repair 4. CHECK FOR LEAKAGE OF REFRIGERANT See: Service and Repair Page 8056 Airbag System Air Bag Deactivation Switch: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 9010 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 8079 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 8219 (1) Wind the seat belt with the retractor. (2) When the seat belt is sufficiently wound, cut the seat belt approximately 100 mm (3.94 in.) from the retractor, as shown in the illustration. HINT The seat belt is designed so that winding the seat belt before pretensioner activation will decrease the pulling power of the seat belt during pretensioner activation. (b) Check if SST is functioning properly. SST : 09082-00700 SST : 09082-00770 CAUTION: When activating a seat belt pretensioner, always use the specified SST. (c) Prepare SST for activation of the seat belt pretensioner. (1) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner. NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (2) Place the front seat outer belt on the ground and cover it with a tire (with wheel). NOTICE: Set up the front seat outer belt as shown in the illustration. Page 209 Headlamp Dimmer Relay: Testing and Inspection LIGHTING: HEADLIGHT DIMMER RELAY: ON-VEHICLE INSPECTION 1. REMOVE HEADLIGHT DIMMER RELAY (DIM) (a) Remove the dimmer relay from the engine room relay box. 2. INSPECT HEADLIGHT DIMMER RELAY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL HEADLIGHT DIMMER RELAY Page 6114 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Engine - Controls - Non-Linear Acceleration From A Stop PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Controls Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 7153 No further tightening is required once the nut is tightened with the specified torque. 2. INSTALL WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 3. INSPECT TIRE (a) Inspect the tire See: Wheels and Tires/Testing and Inspection/Component Tests and General Diagnostics. 4. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration . 5. PERFORM INITIALIZATION (a) Perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 6. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Components Parking Assist Switch: Service and Repair Components PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: COMPONENTS Locations Four Wheel Drive Selector Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 131 Compressor Clutch Relay: Testing and Inspection AIR CONDITIONING: MAGNETIC CLUTCH RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAGNETIC CLUTCH RELAY (MG CLT) (a) Remove the magnetic clutch relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: * If the result is not as specified, replace the relay. (c) Install the magnetic clutch relay. Components Power Steering Pressure Switch: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: COMPONENTS Page 5193 (b) Using union nut wrench, connect the flexible hose to the brake tube while holding the flexible hose with a wrench. without union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf) with union nut wrench - Torque : 14 Nm (145 kgf-cm, 10 ft-lbf) HINT Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). NOTICE: * Do not bend or damage the brake tube. * Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting point. 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 15. FILL RESERVOIR WITH BRAKE FLUID (a) Fill the brake fluid See: Brakes and Traction Control/Brake Bleeding/Service and Repair/Replacement. 16. BLEED BRAKE LINE See: Brakes and Traction Control/Brake Bleeding/Service and Repair/Bleeding 17. CHECK BRAKE FLUID LEVEL IN RESERVOIR See: Brakes and Traction Control/Hydraulic System/Brake Fluid/Testing and Inspection 18. CHECK FOR BRAKE FLUID LEAKS 19. INSTALL REAR WHEEL LH for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 20. INSPECT DIFFERENTIAL OIL See: Differential Assembly/Fluid - Differential/Service and Repair 21. INSPECT FOR DIFFERENTIAL OIL LEAK 22. CHECK PARKING BRAKE PEDAL TRAVEL See: Brakes and Traction Control/Parking Brake System/Adjustments 23. ADJUST PARKING BRAKE PEDAL TRAVEL See: Brakes and Traction Control/Parking Brake System/Adjustments 24. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 25. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 693 Power Mirror Switch: Service and Repair Removal MIRROR: OUTER MIRROR SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 2. REMOVE OUTER MIRROR SWITCH ASSEMBLY (a) Using a screwdriver, detach the 2 claws. HINT Tape the screwdriver tip before use. (b) Remove the outer mirror switch. Page 5545 Standard resistance: (4) If the resistance is not as specified, repair or replace the harness or connector. (c) Check the 4WD control switch. (1) Turn the ignition switch OFF. (2) Connect the L1 switch connector. (3) Connect the A25 and A26 ECU connectors. (4) Measure the voltage according to the value(s) in the table below. Standard voltage: (5) If the voltage is not as specified, check the 4WD control ECU. (d) Check the 4WD control ECU. (1) Disconnect the L1 switch connector. (2) Measure the voltage according to the value(s) in the table below. Page 4185 Page 7722 Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. for Floor Shift Type: Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH (a) for Column Shift Type: Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) for Column Shift Type: Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 7. INSTALL INSTRUMENT SIDE PANEL RH (a) for Column Shift Type: Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 8. INSTALL COWL SIDE TRIM BOARD RH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 9. INSTALL FRONT DOOR SCUFF PLATE RH (a) for Regular Cab: Page 1914 * When you have replaced the transmission hose and/or output shaft oil seal, proceed to the "Fluid Temperature Check" procedures. 3. TRANSMISSION FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. (c) Reinstall the overflow plug. (d) Fill the transmission with the amount of fluid listed in the table below. Reference Capacity: (e) Install the refill plug. HINT If you cannot fill the listed amount of fluid, perform the following: (1) Start the engine and idle it. NOTICE: Check that electrical systems such as the air conditioning system, audio system and lighting system are off. (2) Move the shift lever through the entire gear range to circulate the fluid. (3) Wait for 30 seconds with the engine idling. (4) Stop the engine. (5) Remove the refill plug. (6) Fill the transmission with the remaining fluid until the amount in the table has been filled. (7) Install the refill plug. 4. FLUID TEMPERATURE CHECK Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 3455 CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Bus Buffer ECU Communication Stop Mode - Bus Buffer ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (BUS BUFFER ECU BRANCH WIRE) (a) Disconnect the J59 bus buffer ECU connector. (b) Measure the resistance according to the value(s) in the table below. Page 2695 Water Pump: Service and Repair Installation 1UR-FE COOLING: WATER PUMP: INSTALLATION 1. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and the water pump with the 8 bolts shown in the illustration. for bolt A - Torque : 47 Nm (479 kgf-cm, 35 ft-lbf) for bolt B - Torque : 23 Nm (235 kgf-cm, 17 ft-lbf) for bolt C - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) 2. INSTALL WATER PUMP PULLEY (a) Temporarily install the pulley with the 4 bolts. (b) Using SST, hold the pulley and tighten the 4 bolts. SST : 09960-10010 09962-01000 09963-01000 Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 3. INSTALL WATER INLET HOUSING (a) Install a new gasket to the water pump. (b) Install the water inlet housing with the 3 bolts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 4. CONNECT NO. 5 WATER BY-PASS HOSE (a) Connect the water by-pass hose. Transmission Control Switch Transmission Mode Switch: Diagrams Transmission Control Switch Page 4648 Actuator: Diagrams Page 8238 Page 9257 (b) Attach the claw to install the courtesy light. 4. INSTALL REAR DOOR FRAME GARNISH LH (a) Attach the 4 clips to install the rear door frame garnish. 5. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Attach the 4 claws to install the control switch. 6. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH (a) Connect the connector. (b) Attach the 2 clips to install the rear upper door armrest base panel. 7. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH (a) Attach the 4 claws to install the bezel plug. Page 748 Seat Memory Switch: Service and Repair Removal SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): REMOVAL 1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 2. REMOVE FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE FRONT DOOR ARMREST COVER LH 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE SEAT MEMORY SWITCH (a) Remove the 2 screws and seat memory switch. Locations Headlamp Dimmer Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 4985 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. 3. INSPECT SHIFT SOLENOID VALVE S2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. 4. INSPECT SHIFT SOLENOID VALVE S3 Page 1171 Engine Temperature Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm ball joint lock nut wrench, remove the sensor. (c) Remove the gasket from the sensor. Page 597 Specifications Compression Check: Specifications COMPRESSION Page 8402 Page 2820 Page 9115 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 8386 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY Page 8274 Removal SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for Double Cab): REMOVAL 1. REMOVE REAR SEAT ASSEMBLY (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 2. REMOVE REAR NO. 1 SEAT INNER BELT ASSEMBLY RH Page 3385 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 6816 Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Testing and Inspection Drive Belt: Testing and Inspection 1UR-FE ENGINE MECHANICAL: DRIVE BELT: ON-VEHICLE INSPECTION 1. INSPECT FAN AND GENERATOR V BELT (a) Check the belt for wear, cracks or other signs of damage. (b) If any of the following defects is found, replace the fan and generator V belt. * The belt is cracked. * The belt is worn out to the extent that the cords are exposed. * The belt has chunks missing from the ribs. (c) Check that the belt fits properly in the ribbed grooves. HINT Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and generator V belt correctly. 2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY (a) Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If the result is not as specified, replace the tensioner. Page 5055 09954-03010 09955-03030 09956-03020 7. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal. SST : 09308-10010 8. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 9. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER (a) Remove the bolts B and front differential front support assembly LH. (b) Remove the bolts A. (c) Using a plastic-faced hammer, tap out the bearing retainer. 10. REMOVE DIFFERENTIAL CASE ASSEMBLY (a) Remove the differential case from the differential carrier. 11. REMOVE DIFFERENTIAL DRIVE PINION (a) Set the differential carrier to an overhaul stand as shown in the illustration. Page 2339 Variable Valve Timing Actuator: Diagrams Page 7822 Control Module HVAC: Service and Repair Installation AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: INSTALLATION 1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the amplifier with the 2 screws. (b) for Manual Air Conditioning System: Connect the 2 connectors. (c) for Automatic Air Conditioning System: Connect the 3 connectors. 2. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (a) Install the duct with the screw. 3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY for Column Shift Type: Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. for Floor Shift Type: Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL LOWER INSTRUMENT PANEL for Column Shift Type: Page 3460 INSPECTION PROCEDURE PROCEDURE 1. CHECK HARNESS AND CONNECTOR (ECM - BATTERY AND BODY GROUND) (a) Disconnect the A24 and D74 ECM connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 4933 NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that the ridged side of the cable end is facing upward. (d) Connect the 2 cable clamps with the 2 bolts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) (e) Return the floor carpet to its original position. (f) Move the shift lever to N. (g) Turn the control shaft lever counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position. (h) Connect the control cable with a new clip and the nut. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) Page 1997 Page 5665 Yaw Rate Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 3220 Page 9269 Hood Latch Release Cable: Service and Repair Installation ENGINE HOOD / DOOR: HOOD LOCK CONTROL CABLE ASSEMBLY: INSTALLATION HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY (a) Pass the cable into the engine room. (b) Pass the cable rear side through the grommet until the cable stopper is attached to the grommet. (c) Pass the cable front side through the upper radiator support. (d) Attach the cable to the clamps as shown in the illustration. 2. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY (a) Connect the hood lock control cable to the hood lock lever. (b) Attach the 2 claws to install the hood lock lever 3. INSTALL HOOD LOCK ASSEMBLY (a) Apply MP grease to the sliding areas of the lock. Page 6624 3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 5. REMOVE CENTER FRONT SEAT ASSEMBLY (a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal. 6. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Disconnect the power outlet socket connector. (b) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 7. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. Page 7488 Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL 1. REMOVE ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Disconnect the receiver connector. (b) Remove the bolt and receiver. Page 5309 ^ 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 2503 Oil Pressure Sender: Service and Repair Installation 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Apply adhesive to 2 or 3 threads of the oil pressure sender gauge. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (b) Install the oil pressure sender gauge. Torque : 15 Nm (153 kgf-cm, 11 ft-lbf) NOTICE: Do not start the engine within 1 hour after installation. (c) Connect the sender gauge connector. 2. INSPECT ENGINE OIL LEVEL See: Engine Lubrication/Testing and Inspection 3. INSPECT FOR OIL LEAK See: Engine Lubrication/Engine Oil/Service and Repair/Replacement 4. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 5013 Actuator: Diagrams Up to 11/2009 Traction Control Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 298 J/B No.3 - Instrument Panel Right Page 7648 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 6291 Engine Room R/B, J/B - Engine Compartment Left Page 6158 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 8728 ^ This condition is NOT reception related. Switching modes will not correct the condition. ^ This condition affects XM ONLY - AM/FM reception is normal when this condition occurs. If cycling the ignition key does NOT restore normal operation, this TSB does NOT apply. Warranty Information APPLICABLE WARRANTY ^ Toyota-supplied satellite radio component systems installed as original equipment are warranted for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Toyota-supplied satellite radio components installed by a Toyota dealer are warranted for 12 months, regardless of mileage from the date of installation on the vehicle, or the remainder of the applicable New Vehicle Limited Warranty for 36 months or 36,000 miles, whichever provides the greater coverage. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Order parts through the Pioneer exchange program. Service Exchange Part Identification Countermeasure parts have a "P" marking on the parts label following the Toyota part number (see Figure 1). Required Tools & Equipment NOTE Page 6397 Page 1338 Page 6391 Page 8664 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 6101 (1) Connect the field coil lead wire to terminal C. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Mount the starter in a vise between aluminum plates. (3) Connect the battery and ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current. Standard current: 90 A or less at 11.5 V (5) If the result is not as specified, replace the starter assembly. 2. INSPECT MAGNET STARTER SWITCH ASSEMBLY (a) Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. (2) If the result is not as specified, replace the magnet starter switch assembly. (b) Check if the pull-in coil has an open circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the magnet starter switch assembly. (c) Check if the holding coil has an open circuit. Page 6153 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 8789 AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): INSPECTION 1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Instrument Panel Speaker (for CrewMax) AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): INSPECTION 1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for Standard) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 12 Speakers) (a) Measure the resistance according to the value(s) in the table below. Page 197 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 1648 Power Window Switch: Service and Repair Power Window Master Switch Components WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: COMPONENTS Page 6722 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 6604 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Diagrams Rear Vision Camera: Diagrams Page 2411 Oil Cooler: Overhaul Disassembly 1UR-FE LUBRICATION: ENGINE OIL COOLER: DISASSEMBLY 1. REMOVE OIL PUMP RELIEF VALVE (a) Remove the relief valve plug and gasket. (b) Remove the valve spring and oil pump relief valve. Reassembly 1UR-FE LUBRICATION: ENGINE OIL COOLER: REASSEMBLY 1. INSTALL OIL PUMP RELIEF VALVE (a) Coat the oil pump relief valve with engine oil. (b) Install the relief valve and valve spring into the oil pump cover hole. (c) Install a new gasket and the plug. Torque : 37 Nm (375 kgf-cm, 27 ft-lbf) Page 2574 Variable Valve Timing Actuator Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE VVT SENSOR (a) Disconnect the 4 sensor connectors. (b) Remove the 4 bolts and 4 sensors. Page 6655 (a) for AC Power Supply: Disconnect the clamp. (b) Remove the 3 screws and bezel. 3. REMOVE REAR POWER OUTLET SOCKET (for Standard) (a) Detach the claw and remove the power outlet socket. 4. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard) (a) Detach the 2 claws and remove the power outlet socket cover. 5. REMOVE REAR POWER POINT SOCKET (for AC Power Supply) (a) Detach the 2 claws and remove the power outlet socket. Page 7295 10. ADJUST TOTAL PRELOAD (a) To prevent the steering rack teeth from damaging the oil seal lip, provisionally install the RH and LH steering rack end. (b) Using 32 mm hexagon wrench, torque the rack guide spring cap. Torque : 30 Nm (306 kgf-cm, 22 ft-lbf) (c) Using 32 mm hexagon wrench, loosen the rack guide spring cap. (d) Using SST, turn the control valve to the right and left once or twice. SST : 09616-00011 (e) Using SST, loosen the rack guide spring cap until the rack guide spring ceases to function. (f) Using SST, a torque wrench and 32 mm hexagon wrench, tighten the cap until the preload is within the specification. SST : 09616-00011 Preload (turning): 1.9 to 2.7 N*m (19.4 to 27.5 kgf*cm, 16.8 to 23.9 in.*lbf) (g) Apply adhesive to 2 or 3 threads of the rack guide spring cap nut. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (h) Provisionally install the rack guide spring cap nut. (i) Using SST, hold the rack guide spring cap and using 32 mm hexagon wrench, torque the rack guide spring cap nut. SST : 09922-10010 without SST - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf) Page 47 Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS Page 6299 J/B No.6 Assembly - Instrument Panel Center Page 882 Oil Pressure Sender: Diagrams Oil Pressure Switch Page 7448 Tire Pressure Sensor: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so that the print surface can be seen. NOTICE: * Check that there is no visible deformation, damage or other abnormalities on the tire pressure warning valve and transmitter. * Check that there is no foreign matter on the inner grommet and around the rim hole. * If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be damaged or fail to transmit signals when running at a high speed. * If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before installation. * The transmitter ID registration must be performed for all tire pressure warning valve and transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do not need to be replaced before performing the transmitter ID registration See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration * It is necessary to perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been replaced. (b) If reusing the tire pressure warning valve and transmitter: Install a new grommet. HINT A new tire pressure warning valve and transmitter is supplied with a grommet. (c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut. Page 678 Telescopic Steering Column)/Removal 2. REMOVE LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 3. REMOVE UNLOCK WARNING SWITCH ASSEMBLY (a) Disconnect the unlock warning switch connector. (b) Detach the 3 claws and remove the cover. (c) Remove the contact pin cap. (d) Remove the unlock warning switch. Installation DOOR LOCK: UNLOCK WARNING SWITCH: INSTALLATION 1. INSTALL UNLOCK WARNING SWITCH ASSEMBLY (a) If reusing unlock warning switch assembly: (1) Temporarily install the unlock warning switch. (2) Install the contact pin cap. (3) Attach the 3 claws to install the cover. Page 273 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2063 "Case2" 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 6792 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 7615 Cabin Temperature Sensor / Switch: Diagrams Page 6713 "Case2" 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 3023 Air Flow Meter/Sensor: Diagrams Page 6963 Relay Box: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 396 HINT The wavelength becomes shorter as engine rpm increases. (i) WAVEFORM 8: HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10 minutes or more. (j) WAVEFORM 9: Page 7333 (c) Using SST, disconnect the upper ball joint from the steering knuckle. SST : 09628-62011 (d) Remove the steering knuckle. 7. REMOVE KNUCKLE GREASE RETAINER CAP LH (for 2WD) (a) Using a screwdriver and hammer, tap out the retainer cap. 8. REMOVE STEERING KNUCKLE OIL SEAL LH (for 4WD) (a) Using a screwdriver and hammer, tap out the oil seal. Page 7580 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 7456 Tire Pressure Warning Reset Switch: Testing and Inspection TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION 1. CHECK TIRE PRESSURE WARNING RESET SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power Source Circuit DESCRIPTION When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil, closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and +B2 of the ECM. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN) Page 5281 *1: for 5 leaf spring *2: includes Off road package * If the measured angle is not within the specification, adjust it with the bearing washer (See "Adjust Propeller Shaft Angle"). (c) Measure the No. 3 joint angle. (1) Subtract the angle of the rear differential flange (B) measured before installing the propeller shaft from the angle of the propeller shaft (D) to calculate the No. 3 joint angle. No. 3 joint angle: Angle of propeller shaft (D) - Angle of rear differential flange (B) Measured Value (Reference): Page 1580 Transmission Position Switch/Sensor: Diagrams Page 121 Traction Control Relay: Testing and Inspection BRAKE CONTROL: STOP LIGHT CONTROL RELAY: ON-VEHICLE INSPECTION 1. CHECK STOP LIGHT CONTROL RELAY (a) Remove the stop light control relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) If the result is not as specified, replace the relay. (d) Install the stop light control relay. Page 8162 Air Bag Control Module: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Locations Shift Solenoid: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1413 Page 6228 Diode: Diagrams Diode (Rear Door Courtesy Light) Ultrasonic Sensor (for Front Side) Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Front Side) Components PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): COMPONENTS Page 8644 2. REMOVE CENTER SEAT BACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 4. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 5. REMOVE VIDEO TERMINAL (a) Detach the clamp from the back panel. (b) Detach the 4 claws and remove the video terminal. Installation AUDIO / VISUAL: VIDEO TERMINAL (for Bench Seat Type): INSTALLATION 1. INSTALL VIDEO TERMINAL (a) Attach the 4 claws to install the video terminal. (b) Attach the clamp to the back panel. Page 2075 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 8709 Page 4344 Center Airbag Sensor Assembly (for Floor Shift Type) Impact Sensor: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 4377 Fuel Pump Control Unit: Locations Crew Max Body Page 8379 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): COMPONENTS Components Ignition Switch: Service and Repair Components 1UR-FE STARTING: IGNITION SWITCH: COMPONENTS Page 1588 Transmission Speed Sensor: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL 1. REMOVE SPEED SENSOR NT (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. 2. REMOVE SPEED SENSOR SP2 (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. Page 7932 (1) Place at least 2 tires under the tire which the lower No. 2 instrument panel airbag is tied to. (2) Place at least 2 tires over the tire which the lower No. 2 instrument panel airbag is tied to. The top tire should have a disc wheel installed. NOTICE: * Do not place SST connector under the tires because it could be damaged. * As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. * As the tires may be damaged by the airbag deployment, use tires that you are planning to throw away. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (f) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the tires. (g) Deploy the airbag. (1) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the lower No. 2 instrument panel airbag is tied to. (3) Press SST activation switch to deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tires. HINT The airbag is deployed as the LED of SST activation switch comes on. (h) Dispose of the lower No. 2 instrument panel airbag. Page 5679 2. Loosen the bleeder plug. 3. Using the Techstream, operate the brake actuator, completely depress the brake pedal and hold it there. HINT The operation stops automatically after 4 seconds. When performing this procedure continuously, set an interval of at least 20 seconds. NOTICE: * During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid comes out of the bleeder plug. * Depress and hold the brake pedal. Do not depress and release the pedal repeatedly. (10)4. Tighten the bleeder plug, and then release the brake pedal. 5. Repeat the 3 previous steps until all air in the fluid is completely bled out. 6. Tighten the bleeder plug. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (11)7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure reduction line. (12)Clear the DTCs See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. (13)Inspect for brake fluid leak. (14)Check and adjust brake fluid level in reservoir See: Hydraulic System/Brake Fluid/Testing and Inspection. (15)If any DTC is set, perform the troubleshooting for the DTC (16)Check the DTC See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. Page 4600 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 2771 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 6716 Push the terminal retainer down to the temporary lock position. Page 8804 Speaker: Service and Repair Front Door Speaker (for Double Cab) Components AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): COMPONENTS Diagrams Electronic Noise Suppressor: Diagrams Page 8087 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 2031 Driver Side J/B - Cowl Side Left Page 8875 Alarm Module: Service and Repair Installation THEFT DETERRENT: THEFT WARNING ECU: INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR ECU (a) Install the ECU with the nut. (b) Install the junction block with the 2 nuts. (c) Connect the connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 3. INSTALL INSTRUMENT SIDE PANEL LH Page 7298 SST : 09521-24010 Clearance: 3.0 mm (0.118 in.) or less NOTICE: Be careful not to damage the rack boot No. 1. 16. INSTALL STEERING RACK BOOT NO. 2 CLAMP HINT The installation procedure for the No. 2 side is the same as that for the No. 1 side. 17. INSTALL STEERING RACK BOOT CLIP (a) Using pliers, install the 2 rack boot clips. NOTICE: Make sure that each clip's claws are positioned within the area shown in the illustration. 18. INSTALL TIE ROD END SUB-ASSEMBLY LH (a) Align the matchmarks of the tie rod and rack end and temporarily install the tie rod with the lock nut. (b) After adjusting toe-in, torque the nut. Torque : 82 Nm (836 kgf-cm, 60 ft-lbf) 19. INSTALL TIE ROD END SUB-ASSEMBLY RH HINT The installation procedure for the RH side is the same as that for the LH side. 20. INSTALL STEERING TURN PRESSURE TUBE (a) Coat 4 new O-rings with power steering fluid and install them onto the pressure tubes. (b) Using union nut wrench, install the 2 pressure tubes. Page 1266 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 1556 Tire Pressure Sensor: Service and Repair Disposal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire pressure warning valve and transmitter, remove the battery and dispose of it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Use the tip of a screwdriver to pry off the back cover. (b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that connect the battery to the base board. Page 265 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. Page 4566 Crankshaft Position Sensor: Diagrams Page 1057 Door Switch: Testing and Inspection Rear Door Courtesy Switch LIGHTING: REAR DOOR COURTESY SWITCH: INSPECTION 1. INSPECT REAR DOOR COURTESY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 1484 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Components Neutral Safety Switch: Service and Repair Components A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS Page 9047 Page 8101 Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): COMPONENTS Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION A760F Automatic Transmission System Transfer Case Actuator: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1340 Ignition Switch: Service and Repair Installation 1UR-FE STARTING: IGNITION SWITCH: INSTALLATION 1. INSTALL IGNITION SWITCH ASSEMBLY (a) Attach the 2 claws to install the ignition switch to the steering lock. 2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Reassembly 3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly 4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly 5. INSTALL STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation. (b) for Manual Tilt and Manual Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation. (c) for Power Tilt and Power Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Locations Tire Pressure Monitor Receiver / Transponder: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 6627 Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Floor Shift Type) Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL 1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal Page 6693 Page 6820 Floor Wire Page 6766 AJ1-AJ8 Page 6557 Junction Connector (CAN No.2) - Lower Finish Panel Page 6800 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 173 Page 4465 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Capacity Specifications Refrigerant Oil: Capacity Specifications COMPRESSOR OIL Standard (Oil capacity inside the new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) Page 5410 (4) If the resistance is not as specified, repair or replace the harness or connector. (c) Check the 4WD control switch. (1) Turn the ignition switch OFF. (2) Connect the L1 switch connector. (3) Connect the A25 and A26 ECU connectors. (4) Measure the voltage according to the value(s) in the table below. Standard voltage: (5) If the voltage is not as specified, check the 4WD control ECU. (d) Check the 4WD control ECU. (1) Disconnect the L1 switch connector. (2) Measure the voltage according to the value(s) in the table below. Page 1707 Standard wheel angle (unloaded vehicle): for CrewMax of standard deck Page 439 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 177 Headlamp Alignment Control Module: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 8620 Auxiliary Input / Output Jack: Diagrams Stereo Jack Adapter Locations Shift Interlock Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 2774 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. Components Remote Switch: Service and Repair Components AUDIO / VISUAL: STEERING PAD SWITCH: COMPONENTS Page 1940 (b) Remove the oil filter drain plug. (c) Install the pipe to the oil filter cap. HINT Use a container to catch the draining oil. NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe. (d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as shown in the illustration. (e) Using SST, remove the oil filter cap. SST : 09228-06501 NOTICE: Do not remove the oil filter bracket clip. Page 2904 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Specifications Compression Check: Specifications COMPRESSION Page 7116 Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL 1. REMOVE ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Disconnect the receiver connector. (b) Remove the bolt and receiver. Page 5604 HINT * *1: FR RH * *2: FR LH * *3: RR RH * *4: RR LH * *5: FR Master Cylinder * *6: RR Master Cylinder (b) Using a union nut wrench, disconnect the 2 brake tubes from the VSC actuator. (c) Using a union nut wrench, remove the 2 brake tubes from the brake master cylinder. 4. DISCONNECT BRAKE TUBE (a) Using a union nut wrench, disconnect the 4 brake tubes from the VSC actuator. (b) Remove the clamp from the VSC actuator bracket. 5. REMOVE VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY (a) Remove the 3 nuts and VSC actuator with actuator bracket. Installation Page 1671 Wiper Switch: Service and Repair Installation WIPER AND WASHER: WIPER SWITCH: INSTALLATION 1. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (a) Attach the claw to install the wiper switch. (b) Connect the 2 connectors. 2. INSTALL UPPER STEERING COLUMN COVER (a) Attach the 4 clips to install the upper steering column cover onto the instrument panel cluster finish panel. (b) Attach the claw to install the upper steering column cover. 3. INSTALL LOWER STEERING COLUMN COVER (a) Attach the 2 claws to install the lower steering column cover. NOTICE: Do not damage the tilt and telescopic switch. (b) Using a screwdriver, while turning the steering wheel to the right and left, install the 2 screws and lower steering column cover. Page 6630 5. INSTALL POWER OUTLET SOCKET ASSEMBLY (a) Attach the claw to install the power outlet socket. 6. INSTALL CONSOLE BOX BEZEL (a) Attach the 5 claws to install the console box bezel. (b) Connect the connector. 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 235 Accessory Relay: Diagrams Recall 10V091000: Front Driveshaft Replacement Drive/Propeller Shaft: Recalls Recall 10V091000: Front Driveshaft Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Tundra 2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: March 09, 2010 NHTSA CAMPAIGN ID NUMBER: 10V091000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Axle Assembly: Axle Shaft POTENTIAL NUMBER OF UNITS AFFECTED: 2 SUMMARY: Toyota is recalling certain model year 2010 Tundra vehicles with four wheel drive, there is a possibility that an improper weld exists at the union of the propeller shaft and yoke. Due to this improper weld, this joint may separate and the separated shaft may come into contact with the road surface. CONSEQUENCE: This may result in a loss of vehicle control increasing the risk of a crash. REMEDY: Dealers will replace the front propeller shaft free of charge. The safety recall is expected to begin during March 2010. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2826 HINT The wavelength becomes shorter as engine rpm increases. (i) WAVEFORM 8: HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10 minutes or more. (j) WAVEFORM 9: Page 5090 Parts Information Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle when driving. ^ Install ChassisEAR(TM) (or equivalent) and isolate noise to the rear differential area. ^ Remove the rear differential and axle shafts. Page 8904 (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT The procedures listed below are for the LH side. 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL FRONT DOOR SCUFF PLATE RH (a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT The procedures listed below are for the LH side. Locations Fuse Block: Locations Engine Compartment Page 6723 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 8809 Speaker: Service and Repair Components AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): COMPONENTS Removal AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for Page 4266 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 2044 J/B No.6 Assembly Inner Circuit Engine - Controls - Non-Linear Acceleration From A Stop PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Controls Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 6641 HINT Tape the screwdriver tip before use. 10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 5. INSTALL POWER OUTLET SOCKET ASSEMBLY Adjustments Brake Pedal Assy: Adjustments BRAKE: BRAKE PEDAL: ADJUSTMENT 1. CHECK BRAKE PEDAL HEIGHT (a) Check the brake pedal height. (1) Turn back the carpet. (2) Remove the tibia pad. (3) Measure the shortest distance between the brake pedal surface and dash panel. Standard pedal height from dash panel: 179.9 to 189.9 mm (7.08 to 7.48 in.) NOTICE: Do not adjust the pedal height. Doing so by changing the push rod length will structurally change the pedal ratio. (4) If the pedal height is incorrect, check that there is no damage in the 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 them. 2. CHECK AND ADJUST STOP LIGHT SWITCH ASSEMBLY HINT If the pedal height is incorrect, check and adjust the stop light switch clearance. (a) Disconnect the stop light switch connector. (b) Turn the stop light switch counterclockwise and remove it. (c) Insert the stop light switch until the body hits the cushion. NOTICE: When inserting the stop light switch, support the pedal from behind so that the pedal is not pushed in. (d) Make a quarter turn clockwise to install the stop light switch. NOTICE: The turning torque for installing the stop light switch should be 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less. Page 6751 J/B No.6 Assembly Inner Circuit Page 4338 (4) for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector. (5) for Fuel Hose Connector Cover Type: Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration. (6) Check that there is no fuel leakage. 3. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See: Testing and Inspection. Page 1519 5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Inspect the switch See: Testing and Inspection/Initial Inspection and Diagnostic Overview. Page 2901 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 5032 Differential Carrier: Overhaul Disassembly DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): DISASSEMBLY 1. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using a dial indicator, measure the runout of the companion flange vertically and laterally. Maximum runout: (b) If the runout is greater than the maximum, replace the companion flange. 2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR (a) Using a dial indicator, measure the runout of the ring gear. Maximum runout: 0.05 mm (0.00197 in.) (b) If the runout is greater than the maximum, replace the ring gear with a new one. 3. INSPECT DIFFERENTIAL RING GEAR BACKLASH (a) Using a dial indicator, measure the backlash of the ring gear. Standard backlash: 0.10 to 0.20 mm (0.00394 to 0.00788 in.) Page 9128 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Center Power Outlet Socket (for Column Shift Type) Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Column Shift Type) Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Page 3518 (a) Reconnect the J86 No. 1 junction connector connector. NEXT -- Continue to next step. 4. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR SIDE) (a) Disconnect the J113 No. 2 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) OK -- Continue to next step. 5. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) (a) Disconnect the J94 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 9058 "Case2" 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 6550 Driver Side J/B - Cowl Side Left Page 6165 Page 2797 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 5885 Page 6974 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 2976 SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Page 6707 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. Page 735 OK: (f) If the result is not as specified, replace the switch. 3. INSPECT SEAT HEATER SWITCH LH (w/ Climate Control Seat System) (a) Measure the resistance according to the value(s) in the table below. Standard Resistance (for Heater): Standard Resistance (for Blower): HINT As the dial is being turned, the resistance changes gradually. (b) If the result is not as specified, replace the switch. (c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. OK: (d) If the result is not as specified, replace the switch. (e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. OK: Page 1492 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 6138 Page 365 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 Oxygen Sensor Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5077 Standard Drive Pinion Preload Plus: 39. INSPECT BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (a) Using SST and a dial indicator, measure the ring gear backlash. SST : 09564-33010 Standard backlash: 0.17 to 0.27 mm (0.00670 to 0.0106 in.) 40. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using a dial indicator, measure the runout of the companion flange vertically and laterally. Maximum runout: (b) If the runout is greater than the maximum, replace the companion flange. 41. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT Components Acceleration/Deceleration Sensor: Service and Repair Components BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS Page 7940 NOTICE: Take care not to damage SST wire harness. (5) Connect the red clip of SST to the battery positive (+) terminal and black clip of SST to the battery negative (-) terminal. (g) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag. * Do not apply water to a curtain shield airbag with a deployed airbag. * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) CAUTION: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Remove the curtain shield airbag See: Removal and Replacement/Curtain Shield Airbag Assembly/Removal. (c) Cut off the deployment section of the curtain shield airbag. (d) Using a service-purpose wire harness for the vehicle, tie down the curtain shield airbag to the tire. Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag(s) Arming and Disarming Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.) Page 9349 Rear Fender Liner: Service and Repair Removal EXTERIOR: FENDER LINER (for Rear Side): REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL HOUSE LINER LH (a) Remove the rear wheel house liner (center). (1) Remove the 6 screws. (2) Remove the 9 clips and rear wheel house liner. (b) Remove the rear wheel house liner (front). (1) Remove the 2 screws. (2) Remove the 4 clips and rear wheel house liner. Page 7197 HINT The vane pump rotor can be installed in both directions. (b) Coat the 10 vane pump plates with power steering fluid. (c) Install the vane pump plates with the round end facing outward. NOTICE: Make sure that the vane pump plates are installed facing in the correct direction. 6. INSTALL VANE PUMP SHAFT SNAP RING (a) Using a screwdriver and snap ring expander, install a new shaft snap ring onto the vane pump shaft. 7. INSTALL VANE PUMP REAR HOUSING (a) Coat a new O-ring and straight pin with power steering fluid and install it onto the rear housing. (b) Align the straight pin of the rear housing with the notches of the cam ring, front side plate, and front housing. Components Oil Pressure Sender: Service and Repair Components 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: COMPONENTS Page 8808 Repair/Front Door (for Double Cab)/Reassembly 8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Power Steering Oil Pressure Sensor Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor Page 2645 Radiator Cooling Fan: Service and Repair Removal 1UR-FE COOLING: FAN: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. DRAIN ENGINE COOLANT See: Coolant/Service and Repair 3. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 4. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Removal 5. REMOVE INLET RADIATOR HOSE (a) Remove the radiator hose. 6. REMOVE FAN SHROUD (a) Loosen the 4 nuts holding the fluid coupling fan (b) Remove the fan and generator V-belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. (c) Disconnect the reservoir hose from the upper radiator tank. (d) w/ Trailer Towing System: Detach the claw to open the No. 1 flexible hose clamp. (e) Remove the 2 bolts holding the fan shroud. (f) Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the fluid coupling fan. NOTICE: Page 5786 Parking Brake Warning Switch: Diagrams Emission Control System Canister Purge Solenoid: Locations Emission Control System 1UR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION Page 8772 Speaker: Diagrams Front Side Speaker Page 6043 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 6322 AJ1-AJ8 Page 8185 Seat Occupant Classification Module - Air Bag: Diagrams Page 8364 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Page 6241 Driver Side J/B - Cowl Side Left Page 8259 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for CrewMax): COMPONENTS 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 831 Wheel Speed Sensor: Diagrams Rear Speed Sensor Page 8812 (a) Disconnect the connector. (b) Remove the 4 bolts and box speaker. Installation AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSTALLATION 1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY (a) Install the box speaker with the 4 bolts. HINT Tighten the bolts in the order shown in the illustration. (b) Connect the connector. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): COMPONENTS Page 1589 Transmission Speed Sensor: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION 1. INSTALL SPEED SENSOR SP2 (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. 2. INSTALL SPEED SENSOR NT (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. A760F Automatic Transmission System Transfer Case Actuator: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 6012 Alternator: Testing and Inspection 1UR-FE CHARGING: GENERATOR: INSPECTION 1. INSPECT GENERATOR ROTOR ASSEMBLY (a) Check the rotor for an open circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the generator rotor assembly. (b) Check if the rotor is grounded. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the generator rotor assembly. (c) Check that the slip rings are not rough or scored. If rough or scored, replace the generator rotor assembly. (d) Using a vernier caliper, measure the slip ring diameter. Page 2697 8. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Installation 9. INSTALL FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service and Repair/Installation 10. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT (a) Install the water inlet with thermostat See: Thermostat/Service and Repair/Installation. 11. INSTALL FAN SHROUD (a) Install the fan shroud See: Radiator Cooling Fan/Service and Repair/Installation. Page 998 Fuel Gauge Sender: Diagrams Page 1823 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. Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 8678 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity Without towing package ...................................................................................................................... .......................................................... 12.8 qt (12.1L) With towing package ........................................ .............................................................................................................................................. 13.9 qt (13.2L) Page 8088 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 734 (f) If the result is not as specified, replace the switch. 2. INSPECT SEAT HEATER SWITCH RH (w/ Seat Heater System) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: HINT As the dial is being turned, the resistance changes gradually. (b) If the result is not as specified, replace the switch. (c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. OK: (d) If the result is not as specified, replace the switch. (e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates. Page 3513 NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - ECM)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (4WD CONTROL ECU) OK -- Continue to next step. 22. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - ECM) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (ECM) OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR 23. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) (a) Disconnect the J19 air conditioning amplifier connector. Page 1670 (b) Detach the claw and remove the wiper switch. NOTICE: Do not push the claw with excessive force as it may brake. Components Spark Plug: Service and Repair Components 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS Page 6561 Driver Side J/B Inner Circuit Page 5770 (e) Install the No. 1 parking brake cable and cable retainer with the bolt (labeled E). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) (f) Temporarily install the adjustment nut and lock nut (labeled F). NOTICE: Do not bend and twist the parking brake cable. HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE PEDAL TRAVEL" procedure. 27. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 4180 mm [13 ft. 8.6 in.] Wheelbase Type) (a) Install the No. 1 cable support bracket with the 3 bolts (labeled A). Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) (b) Install the No. 1 parking brake cable to the inside of the vehicle with the 2 bolts (labeled B). Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the 3 clamps (labeled C) to the No. 1 parking brake cable. (d) Install the 3 clamps with the 3 nuts (labeled D). Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (e) Install the No. 1 parking brake cable and cable retainer with the bolt (labeled E). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) (f) Temporarily install the adjustment nut and lock nut (labeled F). NOTICE: Do not bend and twist the parking brake cable. HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE PEDAL TRAVEL" procedure. Page 5184 Removal DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 3. DRAIN DIFFERENTIAL OIL See: Differential Assembly/Fluid - Differential/Service and Repair Page 1160 Crankshaft Position Sensor: Diagrams Page 3706 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. A760F Automatic Transmission System Transfer Case Actuator: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 7579 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. Page 2817 Engine Control Module: Pinout Values and Diagnostic Parameters 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM 1. CHECK ECM (a) Measure the voltage according to the value(s) in the table below. HINT The standard voltage between each pair of ECM terminals is shown in the table below. The appropriate conditions for checking each pair of terminals are also indicated. The result of checks should be compared with the standard voltage for that pair of terminals, displayed in the Specified Condition column. The illustration above can be used as a reference to identify the ECM terminal locations. Page 6250 Page 6053 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 9301 Body Emblem: Service and Repair Name Plate Application Procedure NAME PLATE APPLICATION PROCEDURE Page 2502 Oil Pressure Sender: Service and Repair Removal 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Disconnect the sender gauge connector. (b) Remove the oil pressure sender gauge. Page 4182 Page 7970 CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (f) Install SST. (1) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the front seat side airbag is tied to. (3) Press SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT The airbag is deployed as the LED of SST activation switch comes on. (h) Dispose of the front seat side airbag. CAUTION: Page 3263 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Components Solar Sensor: Service and Repair Components AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): COMPONENTS Page 349 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 3428 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR SHORT IN CAN BUS WIRES (DLC3 BRANCH WIRE) (a) Disconnect the J86 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step. 3. CONNECT CONNECTOR Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Locations Seat Position Sensor: Locations SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Locations Transmission Mode Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 7973 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ROOF HEADLINING ASSEMBLY HINT Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY (a) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 10 bolts and curtain shield airbag. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax): INSTALLATION 1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY (a) Install the curtain shield airbag with the 10 bolts. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) NOTICE: Do not twist the curtain shield airbag when installing it. (b) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. Page 213 Page 773 Acceleration/Deceleration Sensor: Service and Repair Installation BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION 1. INSTALL YAW RATE SENSOR (a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of the sensor bracket. (b) Install the yaw rate sensor with the 2 nuts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * Make sure that the sensor is oriented correctly. * If the sensor is dropped, replace it. * Securely connect the connector. * When installing the sensor, make sure to avoid impacts to the sensor. 2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation 3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning. 6. CHECK YAW RATE SENSOR SIGNAL (a) Check the yaw rate sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 7007 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 6726 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 9392 3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount. 4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse. Page 5879 Steering Angle Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8345 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Up to 11/2009 Traction Control Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 1303 Page 2761 ^ 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 6379 Front Door Wire Page 8796 2. REMOVE BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE NO. 1 BOX SPEAKER ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts and box speaker. Installation AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSTALLATION 1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY (a) Install the box speaker with the 3 bolts. (b) Connect the connector. 2. INSTALL BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 4752 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 6403 Page 7285 Steering Gear: Overhaul Disassembly POWER STEERING: STEERING GEAR: DISASSEMBLY 1. FIX POWER STEERING GEAR ASSEMBLY (a) Using SST, secure the power steering gear. SST : 09612-00012 HINT Tape SST before use. NOTICE: When using a vise, do not overtighten it. 2. REMOVE TIE ROD END SUB-ASSEMBLY LH (a) Put matchmarks on the tie rod end LH and steering rack end. 3. REMOVE TIE ROD END SUB-ASSEMBLY RH HINT Use the same procedures described for the LH side. 4. REMOVE STEERING RACK BOOT CLIP (a) Using pliers, remove the 2 steering rack boot clips. 5. REMOVE NO. 2 STEERING RACK BOOT CLAMP (a) Using pliers, remove the 2 boot clamps as shown in the illustration. Page 358 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 4599 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 1487 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 1191 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSTALLATION 1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Install a new O-ring to the manifold absolute pressure sensor. (b) Install the manifold absolute pressure sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) (c) Connect the manifold absolute pressure sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 8063 Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Components Variable Valve Timing Actuator: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS Page 2055 Locations Central Control Module: Locations NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION m Page 8170 (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components Tire Pressure Warning Reset Switch: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS Page 1314 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 5931 Page 5408 Four Wheel Drive Selector Switch: Diagrams Page 3404 (b) Wait 1 minute and then check the display of the connected ECUs and sensors. NOTICE: ECUs and sensors that are not present will not be displayed. Be careful not to mistake them for communication stop malfunctions. HINT * If the display of an ECU is intermittent during the check, one side of an ECU or sensor branch wire is open. (The signal of the ECU is treated as noise, which affects the response and display of the Techstream.) * The main body ECU checks for proper ECU communication for ECUs that are connected to the CAN MS bus circuit, and the results are displayed on the Techstream. If communication stops between an ECU and the main body ECU for 10 seconds or more, the ECU disappears from the Techstream display. * For communication stop mode of ECUs connected to the CAN MS bus circuit, refer to the DTC flowchart of the respective communication stop. B -- GO TO DTC U1002 FLOWCHART See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1002 C -- GO TO MAIN BODY ECU COMMUNICATION STOP MODE FLOWCHART See: Component Tests and General Diagnostics/Main Body ECU Communication Stop Mode D -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN Communication System/Problem Symptoms Table E -- GO TO OPEN IN ONE SIDE OF CAN BRANCH WIRE FLOWCHART See: Symptom Related Diagnostic Procedures/CAN Communication System A -- Continue to next step. 9. CHECK COMMUNICATION MALFUNCTION DTC (PAST DTC CHECK)* (a) Select "CAN Bus Check" from the "System Select". (b) Write down all of the DTCs stored in each ECU. HINT * If there are communication malfunction DTCs stored but the Techstream's "CAN Bus Check Communication Bus Check" screen displays all of the ECUs and sensors connected to the CAN system, the communication malfunction DTCs may be past malfunctions that are no longer present. * For V bus main wire malfunctions, related ECUs are also detected. Therefore, determine the malfunctioning area based on all of the DTCs that are output. * For MS bus malfunctions, DTCs are output based on the detection of communication stop malfunctions and network malfunctions of ECUs that are connected by the main body ECU. B -- GO TO DTC U1002 FLOWCHART See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1002 Page 3454 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE AIR CONDITIONING AMPLIFIER BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY Bus Buffer ECU Communication Stop Mode Page 6539 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 600 Page 6433 Accessory Relay: Diagrams Page 7365 (b) Using a drill, make a hole in the cylinder between A and B shown in the illustration to discharge the gas inside. CAUTION: * Be careful when drilling because shards of metal may fly about. Always use the proper safety equipment. * For off road type shock absorbers, be extremely careful when drilling it as its gas pressure is much higher than the standard type. NOTICE: The gas is colorless, odorless and nonpoisonous. Components SUSPENSION: REAR SHOCK ABSORBER: COMPONENTS Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power Source Circuit DESCRIPTION When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil, closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and +B2 of the ECM. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN) Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Lock Cylinder Switch: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 5069 15. INSTALL FRONT DIFFERENTIAL CASE 16. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER (a) Install the differential cross shaft bearing retainer and differential support with the 14 bolts. for bolt A - Torque : 65 Nm (633 kgf-cm, 48 ft-lbf) for bolt B - Torque : 155 Nm (1581 kgf-cm, 114 ft-lbf) 17. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING (a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it. SST : 09316-60011 09316-00041 18. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 19. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using SST, install the companion flange. SST : 09950-30012 09951-03010 09953-03010 Locations Shift Solenoid: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Locations Shock Sensor: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Components Engine Temperature Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: COMPONENTS Page 1939 Engine Oil: Service and Repair Replacement 1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT CAUTION: * Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. * Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents. * In order to protect the environment, used oil and used oil filters must be disposed of at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container. (c) Install a new gasket and the oil pan drain plug. Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) 2. REMOVE NO. 1 ENGINE UNDER COVER (a) Remove the 3 screws and 5 bolts. (b) Unhook the engine under cover from the vehicle body as shown in the illustration. 3. REMOVE OIL FILTER ELEMENT (a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe. Components Control Module: Service and Repair Components JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS Body/Frame - Choppy Ride Under Various Conditions Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Choppy Ride Under Various Conditions T-SB-0270-10 September 13, 2010 Choppy Ride Service Category Vehicle Exterior Section Frame/Unibody Market USA Applicability Introduction Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road conditions. A newly designed cab mount has been developed to improve this condition. NOTE The Tundra performs similarly to other long wheelbase trucks on choppy, broken concrete surfaces. The enhanced cab mounts of this TSB reduce the amplitude of body vibrations caused by uneven road surfaces, but they do NOT eliminate the sensation entirely. Customers should be counseled that they will experience an improvement in the condition and their truck will perform better than competitors in identical conditions, but some body Page 3383 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. 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 Center Airbag Sensor Assembly (for Column Shift Type) Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Column Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): COMPONENTS Page 9125 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 5038 Maximum runout: 0.04 mm (0.00158 in.) (c) Remove the differential case from the differential carrier. 22. REMOVE REAR DIFFERENTIAL CASE BEARING (a) Using SST, remove the 2 bearings. SST : 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04061 09957-04010 09958-04011 SST : 09950-60010 09951-00480 HINT Fix the claws of SST to the notches in the differential case. 23. DISASSEMBLE DIFFERENTIAL CASE (a) Using a pin punch and hammer, tap out the straight pin. (b) Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side gear thrust washers. 24. REMOVE REAR DIFFERENTIAL DYNAMIC DAMPER (for Regular Cab Standard Deck) (a) Remove the bolt, washer and dynamic damper. Page 5490 Transfer Case Actuator: Diagrams Page 3939 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 6005 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 3077 Push the terminal retainer down to the temporary lock position. Page 1143 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Page 7706 (a) Connect the connector. (b) Attach the 4 clips to install the panel. 6. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL FRONT CONSOLE BOX 8. INSTALL REAR CONSOLE BOX ASSEMBLY 9. INSTALL CONSOLE BOX CARPET 10. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 11. INSTALL UPPER REAR CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 12. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 13. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 14. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 15. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 16. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 17. INSTALL FRONT PILLAR GARNISH LH 18. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Regular Cab) 19. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Double Cab, CrewMax) 20. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 3217 Page 8533 (a) Connect the connector. (b) Attach the 4 clips to install the panel. 3. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 6. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 9. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 7967 (1) Disconnect the connector (yellow colored) from the front seat side airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect SST connector to the front seat side airbag connector. SST : 09082-00700 SST : 09082-00820 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Installation. (4) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window. (5) Maintaining enough clearance for SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage SST wire harness. (6) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press SST activation switch and deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag. * Do not apply water to a front seat side airbag with a deployed airbag. * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. Page 8081 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Page 1843 ^ 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 6642 (a) Attach the claw to install the power outlet socket. (b) Connect the power outlet socket connector. 6. INSTALL CENTER FRONT SEAT ASSEMBLY (a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation. 7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. 10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS Page 3291 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 2925 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 40 Entertainment System Control Module: Diagrams Page 8354 Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components Water Pump: Service and Repair Components 1UR-FE COOLING: WATER PUMP: COMPONENTS Page 1689 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 3289 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 A/T - Torque Converter Bolt Installation Precautions Torque Converter: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 3907 Variable Valve Timing Actuator: Diagrams Locations Alarm Horn Relay: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 7296 with SST - Torque : 62 Nm (632 kgf-cm, 46 ft-lbf) NOTICE: Turn SST 09922-10010 in the direction shown in the illustration. HINT Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). (j) Recheck the total preload. Preload (turning): 1.9 to 2.7 N*m (19.4 to 27.5 kgf*cm, 16.8 to 23.9 in.*lbf) (k) Remove the RH and LH steering rack ends. (l) Apply MP grease to the control valve as shown in the illustration. (m)Wind vinyl tape around the serrated portion of the control valve. (n) Install the dust cover onto the control valve housing. 11. INSTALL STEERING RACK END SUB-ASSEMBLY (a) Install 2 new claw washers, and provisionally install the 2 steering rack ends. Locations Telescoping Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Components Variable Valve Timing Actuator Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS Page 6457 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 6690 Page 6554 J/B No.4 - Instrument Panel Center Page 3995 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 7823 Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. for Floor Shift Type: Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH (a) for Column Shift Type: Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) for Column Shift Type: Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 7. INSTALL INSTRUMENT SIDE PANEL RH (a) for Column Shift Type: Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 8. INSTALL COWL SIDE TRIM BOARD RH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 9. INSTALL FRONT DOOR SCUFF PLATE RH (a) for Regular Cab: Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5068 09951-00810 09951-00890 12. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST, install the washer and bearing (outer race). SST : 09950-60020 09951-00890 09951-01030 HINT First, fit a washer of the same thickness as the removed washer, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary. 13. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST and a press, press in the bearing (inner race). SST : 09506-35010 14. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION Page 7936 (2) Wind the wire harness around the stud bolts of the front seat side airbag as shown in the illustration. (3) Position the front seat side airbag inside the tire. Tire size: Must exceed the following dimensions Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) CAUTION: * Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the front seat side airbag may become loose due to the shock when the airbag is deployed. * Always tie down the front seat side airbag with the airbag deployment direction facing inside the tire. NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (d) Install SST. (1) Connect SST connector to the front seat airbag connector. SST : 09082-00820 (e) Place the tires. Page 6137 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 2821 Page 5073 (h) If the teeth are not engaged properly, use the following chart to select the appropriate washer for correction. Washer thickness: 23. REMOVE FRONT DRIVE PINION FRONT COMPANION FLANGE SUB-ASSEMBLY See: Front Differential Carrier Assembly/Disassembly 24. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 25. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER See: Front Differential Carrier Assembly/Disassembly 26. REMOVE FRONT DIFFERENTIAL CASE See: Front Differential Carrier Assembly/Disassembly 27. REMOVE DIFFERENTIAL DRIVE PINION See: Front Differential Carrier Assembly/Disassembly 28. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING 29. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer. Page 5749 Brake Master Cylinder: Overhaul Disassembly BRAKE: BRAKE MASTER CYLINDER: DISASSEMBLY 1. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Using a T25 "TORX" socket wrench, remove the screw and reservoir. 2. REMOVE MASTER CYLINDER RESERVOIR GROMMET (b) Remove the 2 grommets. Reassembly BRAKE: BRAKE MASTER CYLINDER: REASSEMBLY 1. INSTALL MASTER CYLINDER RESERVOIR GROMMET (a) Apply a light coat of lithium soap base glycol grease to 2 new grommets and install them onto the master cylinder body. 2. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Install the master cylinder reservoir onto the master cylinder body. (b) Using a T25 "TORX" socket wrench, install the screw. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) Page 4502 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 8798 2. REMOVE NO. 1 BOX SPEAKER ASSEMBLY (a) Disconnect the connector. (b) Remove the 4 bolts and box speaker. Installation AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSTALLATION 1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY (a) Install the box speaker with the 4 bolts. HINT Tighten the bolts in the order shown in the illustration. (b) Connect the connector. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 9140 Connectors Part 4 Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. See: Locations Page 7206 Steering Control Module: Service and Repair Installation POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION 1. INSTALL POWER STEERING ECU ASSEMBLY (a) Install the power steering ECU with the nut. Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf) (b) Connect the power steering ECU connector. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Inspection Air Flow Meter/Sensor: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION 1. INSPECT MASS AIR FLOW METER (a) Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). NOTICE: While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. If the result is not as specified, replace the MAF meter. (b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. OK: There is no foreign material. (c) If the result is not as specified, replace the mass air flow meter. (d) Check the IAT sensor. Page 5006 Wiring Harness: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION 1. INSTALL TRANSMISSION WIRE (a) Coat a new O-ring with ATF, and install it to the transmission wire connector. (b) Install the transmission wire with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the transmission wire connector. HINT Push up the lever until the claw of the transmission wire connector makes a connection sound. 2. CONNECT TRANSMISSION WIRE (a) Connect the 9 solenoid valve connectors. (b) Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts. for bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for bolt B - Torque : 11 Nm (112 kgf-cm, 8 ft-lbf) HINT Each bolt length is indicated below. 12 mm (0.472 in.) for bolt A (b) 36 mm (1.41 in.) for bolt B (c) Attach the wire harness to the 2 clamps. 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY Page 4311 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 4376 Fuel Pump Control Unit: Locations Double Cab Body Page 8068 CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for Regular Cab) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): ON-VEHICLE INSPECTION 1. CHECK SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the side airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 2001 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 2241 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 2805 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 2077 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 4923 (a) Attach the 3 claws to install the ECU to the floor shift. (b) Connect the shift lock solenoid connector. 2. INSTALL SHIFT LOCK RELEASE BUTTON (a) Attach the 2 claws to install the button. (b) Attach the 4 claws to install the position indicator housing. 3. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Align the wire with the key part of the transmission floor shift assembly, and install the wire. Then rotate the wire clockwise until it locks. (b) Securely connect the 2 wire terminals to terminal 4 (ILL+) and 8 (ILL-) of the transmission control switch connector. Then push in the connector housing retainer to lock it. Page 4186 Page 9217 6. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Front Door Speaker (for Double Cab)/Removal 7. REMOVE COURTESY LIGHT ASSEMBLY (a) Detach the claw and remove the courtesy light from the door trim board. (b) Disconnect the connector. 8. REMOVE FRONT DOOR ARMREST COVER LH 9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Remove the 2 screws. (b) Using a clip remover, remove the clip. (c) Detach the 9 clips and remove the trim cover. Then disconnect the connector. (d) Disconnect the 2 cables from the inside handle. Page 2019 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 1980 ACC Cut Relay Power Distribution Relay: Testing and Inspection ACC Cut Relay 1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION 1. REMOVE ACC CUT RELAY (a) Remove the clip. (b) Detach the 2 clips and remove the cowl side trim board RH. (c) Remove the relay. 2. INSPECT ACC CUT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL ACC CUT RELAY (a) Install the relay. (b) Attach the 2 clips to install the cowl side trim board RH. (c) Install the clip. Page 7949 SST : 09082-00700 SST : 09082-00780 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window. (4) Maintaining enough clearance for SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage SST wire harness. (5) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press SST activation switch and deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The front passenger airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front passenger airbag with a deployed airbag. * Do not apply water to a front passenger airbag with a deployed airbag. * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Remove the front passenger airbag See: Removal and Replacement/Front Passenger Airbag Assembly/Removal. CAUTION: Page 7485 Tire Pressure Monitor Receiver / Transponder: Diagrams Page 6239 Engine Room R/B, J/B - Engine Compartment Left Page 3824 Manifold Pressure/Vacuum Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSPECTION 1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Check the resistance. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the manifold absolute pressure sensor. Page 2138 Tire Pressure Module: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL NOTICE: * It is necessary to perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. * When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU using the intelligent tester or Techstream and write them down before removal. 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the ECU connector. (b) Remove the 2 nuts and ECU. Page 6300 Junction Connector (CAN No.2) - Lower Finish Panel Page 2951 Manifold Pressure/Vacuum Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Disconnect the manifold absolute pressure sensor connector. (b) Remove the screw and manifold absolute pressure sensor. (c) Remove the O-ring from the manifold absolute pressure sensor. Page 5091 ^ Inspect the axles and rear differential axle housing oil baffles. ^ Install new rear differential axle housing oil baffle(s). ^ Reinstall rear axle shaft and differential and confirm proper operation. Repair Procedure 1. Test drive the vehicle and confirm the condition. Is the noise loudest from the rear of the vehicle? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. 2. Install ChassisEAR(TM) (or equivalent) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest from the rear differential area? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. 3. Remove the rear axle shafts and rear differential. Refer to the Technical Information System (TIS) applicable model year Tundra Repair Manual: 4. Inspect the rear axle housing oil baffles and axle shafts. Are the rear axle housing baffle(s) deformed or are there wear marks on the axle shaft(s) assembly? See Figures 1 and 2 for reference. ^ YES - Go to step 5. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 3313 Engine Control Module: Diagrams Page 3964 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 5667 Yaw Rate Sensor: Testing and Inspection BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION 1. CHECK YAW RATE SENSOR (a) Check the yaw rate sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 6984 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 7031 for CrewMax of standard deck Components Ignition Switch: Service and Repair Components 1UR-FE STARTING: IGNITION SWITCH: COMPONENTS Page 6645 7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 5. INSTALL POWER OUTLET SOCKET ASSEMBLY Components Front Crankshaft Seal: Service and Repair Components 1UR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: COMPONENTS Page 5689 Brake Pedal Assy: Service and Repair Installation BRAKE: BRAKE PEDAL: INSTALLATION 1. INSTALL BRAKE PEDAL PAD (a) Install the brake pedal pad onto the brake pedal. 2. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Install the brake pedal support with the 4 nuts. Torque : 15 Nm (155 kgf-cm, 11 ft-lbf) (b) Install the No. 3 brake pedal bracket to the brake pedal support. (c) Temporarily install the brake pedal support, No. 3 brake pedal bracket and brake pedal lever with the bolt and nut. (d) Install the bolt to the No. 3 brake pedal bracket. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) (e) Apply a light coat of lithium soap base glycol grease to the inner surface of the hole on the brake pedal and return spring mounting bracket of the No. 3 brake pedal bracket. (f) Install the brake pedal return spring. (g) Tighten the bolt and nut. Torque : 23 Nm (239 kgf-cm, 17 ft-lbf) 3. INSTALL PUSH ROD PIN (a) Apply a light coat of lithium soap base glycol grease to the inner surface of the hole on the brake pedal lever. (b) Set the push rod clevis in place, insert the push rod pin from outside the vehicle and then install a new clip. NOTICE: After assembly, check that the pedal operates smoothly. 4. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER Page 3332 HINT The wavelength becomes shorter as the engine rpm increases. (n) WAVEFORM 13: HINT The waveform varies depending on the CAN communication signal. (o) WAVEFORM 14: HINT The waveform varies depending on the CAN communication signal. (p) WAVEFORM 15: HINT The wavelength becomes shorter as the engine rpm increases. Page 1653 Removal WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH (a) Using a screwdriver, detach the 2 clips and 5 claws, and remove the rear upper door armrest base panel. Page 8113 Diagrams Trailer Brake Control Module: Diagrams Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Gear Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 1915 NOTICE: The ATF temperature can be confirmed by using the Techstream. (a) Turn the ignition switch off. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Enter the following menus: Powertrain / ECT / Data List / A/T Oil Temperature 1. (e) Check the ATF temperature. NOTICE: If the ATF temperature is higher than 59°C (138°F), turn the ignition switch off and wait until the fluid temperature drops to between 53 and 59°C (127 and 138°F). 5. FLUID LEVEL CHECK NOTICE: * It is necessary to change to temperature detection mode in order to idle the vehicle appropriately. * The ATF temperature must be between 53 and 59°C (127 and 138°F) to accurately check the fluid level. (a) When using the Techstream: Enter the following menus: Powertrain / ECT / Active Test / Connect the TC and TE1. Standard condition: Indicator lights in the combination meter blink. (b) When not using the Techstream: Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST : 09843-18040 Standard condition: Indicator lights in the combination meter blink. (c) Start the engine and idle it. NOTICE: Check that electrical systems such as the air conditioning system, audio system and lighting system are off. (d) Slowly move the shift lever from P to S, and then change the gear from 1st to 5th. Then return the shift lever to P. HINT Slowly move the shift lever to circulate the fluid through each part of the transmission. (e) Move the shift lever to D, and quickly move it back and forth between N and D (once within 1.5 seconds) for at least 6 seconds. This will activate the fluid temperature detection mode. Page 3827 Manifold Pressure/Vacuum Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Disconnect the manifold absolute pressure sensor connector. (b) Remove the screw and manifold absolute pressure sensor. (c) Remove the O-ring from the manifold absolute pressure sensor. Page 5447 Four Wheel Drive Selector Switch: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE 4WD CONTROL SWITCH (a) Detach the 3 claws to remove the switch. Page 6904 Page 2213 Tire Pressure Warning Reset Switch: Diagrams Page 2676 Engine Temperature Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Coolant/Service and Repair 4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm ball joint lock nut wrench, remove the sensor. (c) Remove the gasket from the sensor. Page 8674 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 8207 Seat Belt: Testing and Inspection Front Seat Outer Belt Assembly (for Center Seat) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): INSPECTION 1. INSPECT CENTER FRONT SEAT BELT ASSEMBLY RH CAUTION: Do not disassemble the retractor. (a) Before installing the seat belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Components Hood Shock / Support: Service and Repair Components ENGINE HOOD / DOOR: HOOD SUPPORT: COMPONENTS Page 8261 (a) Remove the bolt and disconnect the seat belt anchor. HINT The rear No. 1 seat inner belt is fixed with the same bolt as the rear center seat outer belt's anchor. Therefore, it becomes disconnected when the bolt is removed. 4. REMOVE REAR SEAT CUSHION COVER WITH PAD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 5. REMOVE REAR SEATBACK BOARD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 6. REMOVE REAR SEAT ARMREST ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 7. REMOVE REAR SEAT HEADREST ASSEMBLY LH 8. REMOVE CENTER REAR SEAT HEADREST ASSEMBLY 9. REMOVE REAR SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 10. REMOVE REAR SEATBACK LOCK STRIKER COVER LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 11. REMOVE REAR SEAT LOCK CONTROL LEVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 12. REMOVE LOWER REAR SEATBACK COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 13. REMOVE REAR SEATBACK COVER WITH PAD See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 14. REMOVE CENTER RECLINING ADJUSTER INSIDE COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 15. REMOVE REAR SEATBACK HINGE COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly 16. REMOVE REAR SEAT SHOULDER BELT HOLE COVER (a) Remove the screw and the cover. Components Tire Pressure Module: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS Page 4597 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Inspection Variable Valve Timing Actuator: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the camshaft timing oil control valve assembly. (c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and check the movement of the valve. OK: (d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC may be output. Page 3721 NG -- REPLACE RELAY OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 4. INSPECT ECM (IGSW VOLTAGE) (a) Disconnect the ECM connectors. (b) Turn the ignition switch to ON. (c) Measure the voltage according to the value(s) in the table below. Page 816 Traction Control Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6375 Page 3348 Engine Temperature Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the sensor. (b) Using a 19 mm ball joint lock nut wrench, install the sensor. Torque : 20 Nm (200 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench See: Service Precautions (c) Connect the sensor connector. 2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 6629 HINT Tape the screwdriver tip before use. 7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. Page 7634 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Specifications Water Pump: Specifications WATER PUMP ASSEMBLY Install a new gasket and the water pump with the 8 bolts shown in the illustration. For bolt A - Torque............................................................................................................................... ....................................47 Nm (479 kgf-cm, 35 ft-lbf) For bolt B - Torque............................................................................................................................... ....................................23 Nm (235 kgf-cm, 17 ft-lbf) For bolt C - Torque............................................................................................................................... ....................................20 Nm (204 kgf-cm, 15 ft-lbf) Page 367 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 5945 Page 9266 Page 2473 Crankshaft Main Bearing Seal: Service and Repair Installation 1UR-FE ENGINE MECHANICAL: REAR CRANKSHAFT OIL SEAL: INSTALLATION 1. INSTALL REAR CRANKSHAFT OIL SEAL (a) Apply MP grease to the lip of a new oil seal. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST : 09223-56010 NOTICE: * Keep the lip free from foreign matter. * Do not tap on the oil seal at an angle. 2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation 3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (a) for 2WD: Refer to the following procedures . (b) for 4WD: Refer to the following procedures See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 6047 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3508 OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR 13. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU) (a) Disconnect the J28 combination meter ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU (CANH, CANL) OK -- REPLACE COMBINATION METER ASSEMBLY 14. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU) (a) Disconnect the J2 main body ECU connector. Page 7946 Tire size: Must exceed the following dimensions Width 185 mm (7.28 in.) Inner diameter 360 mm (14.2 in.) (2) Tie the lower No. 1 instrument panel airbag to the tire with several wire harnesses. CAUTION: * Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the lower No. 1 instrument panel airbag may become loose due to the shock when the airbag is deployed. * Always tie down the lower No. 1 instrument panel airbag with the airbag deployment side facing inside the tire. NOTICE: As the tire may be damaged by the airbag deployment, use a tire that you are planning to throw away. (d) Connect SST connector to the lower No. 1 instrument panel airbag. SST : 09082-00780 (e) Place tires. (1) Place at least 2 tires under the tire which the lower No. 1 instrument panel airbag is tied to. (2) Place at least 2 tires over the tire which the lower No. 1 instrument panel airbag is tied to. The top tire should have a disc wheel installed. NOTICE: * Do not place SST connector under the tires because it could be damaged. * As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. * As the tires may be damaged by the airbag deployment, use tires that you are planning to throw away. (3) Tie the tires together with 2 wire harnesses. Page 3171 Accelerator Pedal Position Sensor: Diagrams Symptom Related Diagnostic Procedures Axle Shaft Assembly: Symptom Related Diagnostic Procedures AXLE: AXLE SYSTEM: PROBLEM SYMPTOMS TABLE HINT Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Page 8208 Seat Belt: Testing and Inspection Front Seat Outer Belt Assembly (for CrewMax) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): INSPECTION 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY CAUTION: Do not disassemble the retractor. (a) Before installing the seat belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) for Passenger's Seat only: Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Page 5966 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 4068 (f) Disconnect the wire harness clamp. (g) Remove the 4 bolts and canister. Page 6051 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 3634 Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch Page 8381 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 565 Page 7664 Removal AIR CONDITIONING: COMPRESSOR (for 1UR-FE): REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair 2. REMOVE FENDER APRON MUDGUARD SEAL LH Page 3663 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 7064 (e) * for 5 leaf spring 7. ADJUST CAMBER AND CASTER HINT After the camber has been adjusted, inspect the toe-in. (a) Loosen the toe adjusting cam bolt and camber adjusting cam nut. (b) Turn the toe adjusting cam and camber adjusting cam in both directions, and adjust the camber and caster to the center value. HINT The camber and caster should be as close as possible to the center value. Page 4977 Transmission Speed Sensor: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL 1. REMOVE SPEED SENSOR NT (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. 2. REMOVE SPEED SENSOR SP2 (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Locations Steering Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 2728 Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (b) Connect the air fuel ratio sensor connector. (c) Connect the front No. 3 exhaust pipe to the exhaust pipe support. (d) Install a new gasket and the front No. 3 exhaust pipe to the front No. 2 exhaust pipe with the 2 bolts and 2 new nuts. Torque : 48 Nm (489 kgf-cm, 35 ft-lbf) 10. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Installation 11. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 12. INSTALL CENTER EXHAUST PIPE ASSEMBLY (a) Connect the center exhaust pipe to the 3 exhaust pipe supports. (b) Install 2 new gaskets to the front exhaust pipes. (c) Install the center exhaust pipe with the 4 bolts. Torque : 48 Nm (489 kgf-cm, 35 ft-lbf) 13. INSTALL TAILPIPE ASSEMBLY (a) Connect the tailpipe to the exhaust pipe support. (b) Install a new gasket to the center exhaust pipe. Page 7079 Steering Column Control Module: Service and Repair Installation STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): INSTALLATION 1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU (a) Install the ECU with the 2 screws. Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Installation 6. INSTALL LOWER STEERING COLUMN COVER (a) Attach the 2 claws to install the steering column lower cover. 7. INSTALL UPPER STEERING COLUMN COVER Page 7869 4. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) (a) Install the damper servo with the 3 screws, as shown in the illustration. (b) Connect the connector. 5. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. 6. INSTALL BLOWER CASE SUB-ASSEMBLY (a) Attach the 3 claws to install the case. (b) Install the 3 screws. Page 9080 Trailer Towing Part 2 Engine Controls - ECM Update For Shift Performance PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 1307 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. Page 1097 (b) Using a screwdriver, detach the claw and remove the windshield wiper switch. HINT Tape the screwdriver tip before use. NOTICE: If the claw is pressed forcefully, it will break. 16. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Disconnect the connector. (b) While loosening the band clamp as shown in the illustration, detach the claw to remove the headlight dimmer switch. NOTICE: If the claw is pressed forcefully, it will break. Page 6394 Page 4237 Accelerator Pedal Position Sensor: Diagrams Page 8336 Impact Sensor: Testing and Inspection Front Airbag Sensor SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE INSPECTION 1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If the front airbag sensor has defects as mentioned below, replace it with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. 3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: * For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the front airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 6719 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 8043 Clockspring Assembly / Spiral Cable: Diagrams Sprial Cable, Cruise Control Switch Page 1032 Brake Light Switch: Service and Repair Removal LIGHTING: STOP LIGHT SWITCH: REMOVAL 1. REMOVE STOP LIGHT SWITCH ASSEMBLY (a) Disconnect the connector. (b) Rotate the stop light switch in the direction of the arrow and remove it. 2. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER (a) Detach the 2 claws and remove the adjuster. Page 6227 Diode: Diagrams Diode (Ignition) Page 6275 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Bleeding Brake Bleeding: Service and Repair Bleeding BRAKE: BRAKE FLUID: BLEEDING NOTICE: * Perform fluid replacement with the parking brake applied. * Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir. * Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off immediately. * After adding brake fluid, make sure the reservoir is sufficiently full. * When bleeding air, select the suitable procedure listed below. 1. BLEED BRAKE LINE (a) Bleed brake line (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (7) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. (10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (13)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (b) Check and bleed brake system. (1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform the following air bleed procedures. Front Occupant Classification Sensor Seat Occupant Sensor: Diagrams Front Occupant Classification Sensor Page 200 Page 6485 Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Page 2829 (q) WAVEFORM 16: HINT The wavelength changes when the air injection control driver detects malfunctions in the air injection system See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0412 (r) WAVEFORM 17: Components Positive Crankcase Ventilation Valve: Service and Repair Components 1UR-FE EMISSION CONTROL: PCV VALVE: COMPONENTS Page 8852 (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 3 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 2. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 4. INSTALL REAR DOOR ARMREST COVER LH 5. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 6. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 7. INSTALL REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL From 11/2009 AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL REAR NO. 1 SPEAKER ASSEMBLY (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 3 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 2. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly Page 3298 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 5755 Page 8090 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 5372 Four Wheel Drive Selector Switch: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION 1. INSTALL 4WD CONTROL SWITCH (a) Attach the 3 claws to install the switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 6339 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 3791 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 6021 4. REMOVE GENERATOR COIL ASSEMBLY (a) Remove the 4 bolts. (b) Using SST, remove the coil assembly. SST : 09950-40011 09951-04020 09952-04010 09953-04020 09954-04010 09955-04071 09957-04010 09958-04011 (c) Remove the generator washer. 5. REMOVE GENERATOR ROTOR ASSEMBLY 6. REMOVE GENERATOR DRIVE END FRAME BEARING (a) Remove the 4 screws and retainer plate. Components Ignition Switch: Service and Repair Components 1UR-FE STARTING: IGNITION SWITCH: COMPONENTS Page 3714 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 7765 (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation. 5. INSTALL FRONT WIPER MOTOR AND BRACKET (a) Install the front wiper motor and bracket See: Wiper and Washer Systems/Wiper Motor/Service and Repair/Installation. 6. CONNECT HEATER WATER INLET HOSE AND HEATER WATER OUTLET HOSE (a) Connect the 2 heater water hoses and attach the 2 clips. 7. CONNECT SUCTION PIPE SUB-ASSEMBLY AND LIQUID TUBE (a) Remove the attached vinyl tape from the tubes. (b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the suction pipe sub-assembly and liquid tube. Compressor oil: ND-OIL 8 or equivalent (c) Install the 2 O-rings on the suction pipe sub-assembly and liquid tube. (d) Connect the suction pipe sub-assembly and liquid tube. HINT After the connection, check that the claw of the piping clamp is engaged. (e) Attach the plate as shown in the illustration and install the bolt. Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) Page 3777 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 1360 Air Bag Deactivation Switch: Diagrams Curtain Airbag Cutoff Switch Page 2209 Tire Pressure Sensor: Service and Repair Disposal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire pressure warning valve and transmitter, remove the battery and dispose of it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Use the tip of a screwdriver to pry off the back cover. (b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that connect the battery to the base board. Page 5633 Traction Control Switch: Diagrams Page 5964 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 523 Tire Pressure Module: Diagrams CAN Communication System Body Control Module: Locations CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 6916 Push the terminal retainer down to the temporary lock position. Page 3337 Engine Control Module: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and Repair/Removal 3. DISCONNECT CONNECTOR HOLDER BLOCK (a) Remove the connector holder block cover. (b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in the next step. 4. REMOVE ECM (a) Disconnect the wire harness clamp. (b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration. NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before disconnecting the connectors. Failure to do this may cause the connectors to break. (c) Disconnect the 2 connectors. (d) Remove the 4 bolts and ECM. 5. REMOVE GASKET (a) Peel off the rubber part of the gasket. Page 7771 (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 14. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Remove the 3 screws and plate. (b) Detach the 3 claws and remove the heater clamp. (c) Remove the heater radiator unit. 15. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (a) Remove the packing. (b) Remove the 6 screws and detach the 4 claws. Page 3241 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 8568 Parking Assist Distance Sensor: Diagrams Locations Transmission Temperature Sensor/Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 7035 for CrewMax of standard deck Page 1686 for Double Cab of Long Deck Page 5488 Transfer Case Actuator: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 7577 Page 8827 Removal AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Page 7983 1. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY (a) Attach the 5 hooks (A). (b) Attach the 5 hooks (B) and install the front passenger airbag on the instrument panel. (c) Install the 2 screws. (d) Connect the 2 connectors and install the instrument panel wire to the front passenger airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 2. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly 3. INSTALL NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly 4. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly 5. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY HINT * Refer to the procedures from "INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY" (for Column Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation * Refer to the procedures from "INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY" (for Floor Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY: COMPONENTS Engine Controls - ECM Update For Shift Performance PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 8481 Page 2346 Variable Valve Timing Actuator: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. Page 7985 (b) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY: INSTALLATION 1. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Install the 3 bolts to install the instrument panel airbag. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL COWL SIDE TRIM BOARD RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK SRS WARNING LIGHT Page 9091 Page 3576 Page 6154 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Locations Door Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Components Four Wheel Drive Selector Switch: Service and Repair Components JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS Page 6472 Push the terminal retainer down to the temporary lock position. Page 5429 Control Module: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION 1. INSTALL 4WD CONTROL ECU (a) Install the ECU with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. Page 5756 Page 2910 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 6348 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 7656 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 1269 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Page 5290 (c) Measure dimension A between the snap ring grooves. (d) Insert the spider bearing into the spider journal portion, and then measure dimension B of the universal joint. NOTICE: When measuring dimension B, fix the spider and needle roller bearings in a vise and hold them firmly together. (e) Select snap rings to make dimensions A and B the same. Snap ring type: NOTICE: * Use new snap rings. * If possible, use snap rings of the same thickness for both edges. (f) Insert the spider into the flange yoke, and then using SST, press in the spider bearing into the snap ring groove. SST : 09332-25010 HINT Press in the spider bearing on the opposite side in the same way. NOTICE: When pressing in the spider bearing, be careful not to damage its lip. Page 3836 A/F and 02 Sensor Identification Page 7006 Driver Side J/B Inner Circuit Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Oil Capacity ............................................................................................................................................... ............................................................ 1.2 qt (1.12L) Page 9026 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 2673 Engine Temperature Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Partially immerse the sensor in water and warm up the water. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the engine coolant temperature sensor. NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. HINT If the result is as specified, do not replace the engine coolant temperature sensor. Components Steering Column Control Module: Service and Repair Components STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): COMPONENTS Components Drive Belt: Service and Repair Components 1UR-FE ENGINE MECHANICAL: DRIVE BELT: COMPONENTS Page 276 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 2566 Variable Valve Timing Actuator: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION 1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) Page 6915 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Diagrams Fuel Injector: Diagrams Page 7984 Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE COWL SIDE TRIM BOARD RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 5. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 8. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Remove the 3 bolts and remove the instrument panel airbag. Page 7933 CAUTION: * The lower No. 2 instrument panel airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag with a deployed airbag. * Do not apply water to a lower No. 2 instrument panel airbag with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the lower No. 2 instrument panel airbag from the tire. (2) Place the lower No. 2 instrument panel airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Front Seat Side Airbag Assembly (except Fold Down Seat Type) SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold Down Seat Type): DISPOSAL HINT When scrapping a vehicle equipped with the SRS or disposing of the front seat side airbag, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a front seat side airbag that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the airbag. * The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag. * Do not apply water to a front seat side airbag with a deployed airbag. * Always wash your hands with water after completing the operation. * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal for manual seat, See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Page 5607 Hydraulic Control Assembly - Antilock Brakes: Overhaul Disassembly BRAKE CONTROL: BRAKE ACTUATOR: DISASSEMBLY 1. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (a) Using a T30 "TORX" wrench, remove the 3 screws and actuator bracket. Reassembly BRAKE CONTROL: BRAKE ACTUATOR: REASSEMBLY 1. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (a) Using a T30 "TORX" wrench, install the actuator bracket with the 3 screws. Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf) Page 6911 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 5626 Traction Control Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8100 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Page 3406 * If CAN communication system DTCs are output, the trouble cannot be determined solely from the DTCs. Perform troubleshooting according to "HOW TO PROCEED WITH TROUBLESHOOTING" See: CAN Communication System/How to Proceed With Troubleshooting (a) MULTIPLEX TILT AND TELESCOPIC ECU HINT DTC communication uses the CAN communication system. (b) MAIN BODY ECU HINT DTC communication uses the CAN communication system. (c) ECM HINT The ECM is connected to the CAN communication system but CAN communication DTCs are not output. (d) SKID CONTROL ECU WITH ACTUATOR HINT DTC communication uses the CAN communication system. (e) COMBINATION METER ECU HINT DTC communication uses the CAN communication system. (f) AIR CONDITIONING AMPLIFIER HINT DTC communication uses the CAN communication system. (g) STEERING ANGLE SENSOR HINT Page 9243 (b) Attach the claw to install the courtesy light. 4. INSTALL REAR DOOR FRAME GARNISH LH (a) Attach the 5 clips to install the rear door frame garnish. 5. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Attach the 4 claws to install the regulator switch. 6. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH (a) Connect the connector. (b) Attach the 2 clips to install the rear door armrest upper base panel. 7. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH (a) Attach the 4 claws to install the bezel plug. Page 6127 Starter Relay: Testing and Inspection 1UR-FE STARTING: STARTER RELAY: ON-VEHICLE INSPECTION 1. REMOVE STARTER RELAY (ST) (a) Remove the engine room relay box cover. (b) Remove the starter relay from the engine room relay block. 2. INSPECT STARTER RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL STARTER RELAY Page 894 Variable Valve Timing Actuator Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE VVT SENSOR (a) Disconnect the 4 sensor connectors. (b) Remove the 4 bolts and 4 sensors. Starter (for 1.6 Kw Type) Starter Motor: Testing and Inspection Starter (for 1.6 Kw Type) 1UR-FE STARTING: STARTER (for 1.6 kW Type): INSPECTION 1. INSPECT STARTER ASSEMBLY CAUTION: As a large electric current passes through the cable during this inspection, a think cable must be used. If not, the cable may became hot and cause injury. NOTICE: Perform each of the following tests within 3 to 5 seconds. (a) Perform a pull-in test. (1) Remove the nut, and then disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward. If the clutch pinion gear does not move, replace the magnet starter switch assembly. (b) Perform a holding test. (1) When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the magnet starter switch assembly. (c) Inspect the clutch pinion gear return. (1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward. If the clutch pinion gear does not return inward, replace the magnet starter switch assembly. (d) Perform an operation test without load. Page 4422 Fuel Pump Control Unit: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6640 3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 5. REMOVE CENTER FRONT SEAT ASSEMBLY (a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal. 6. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Disconnect the power outlet socket connector. (b) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 7. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. Page 2292 (a) Apply a light coat of engine oil to the O-ring. (b) Install a new O-ring to the oil control valve. (c) Install the oil control valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Connect the oil control valve connector. 5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation 6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 6817 Page 9404 (a) Attach the clip to install the lower radiator grille bracket. (b) Install the bolt and nut. Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf) 2. INSTALL LOWER RADIATOR GRILLE BRACKET RH HINT Use the same procedures described for the LH side. 3. INSTALL RADIATOR GRILLE SUB-ASSEMBLY (a) Attach the 5 clips to install the radiator grille. (b) Install the 10 bolts. Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf) (c) Install the 2 bolts. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) Removal EXTERIOR: RADIATOR GRILLE: REMOVAL 1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (a) Put protective tape around the radiator grille. Page 5871 Parking Brake Warning Switch: Testing and Inspection PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake System/Parking Brake Pedal/Service and Repair/Overhaul/Disassembly 2. CHECK PARKING BRAKE SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the parking brake switch assembly. 3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake System/Parking Brake Pedal/Service and Repair/Overhaul/Reassembly Testing and Inspection Oil Cooler: Testing and Inspection 1UR-FE LUBRICATION: ENGINE OIL COOLER: INSPECTION 1. INSPECT OIL COOLER ASSEMBLY (a) Check the oil cooler for damage or clogging. If necessary, replace the oil cooler assembly. 2. INSPECT OIL PUMP RELIEF VALVE (a) Coat the relief valve with engine oil. (b) Check that the relief valve falls smoothly into the valve hole by its own weight. If the relief valve is not as specified, replace it. If necessary, replace the oil filter bracket. Locations Tilt Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Page 2095 Relay Box: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Removal and Replacement Suspension Strut / Shock Absorber: Removal and Replacement Components SUSPENSION: FRONT SHOCK ABSORBER: COMPONENTS Page 5328 Control Module: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE 4WD CONTROL ECU (a) Disconnect the 2 ECU connectors. (b) Remove the bolt and ECU. Page 5606 Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench See: Service Precautions 3. INSTALL BRAKE TUBE (a) Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench See: Service Precautions (b) Using a union nut wrench, connect the 2 brake tubes to the VSC actuator. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench See: Service Precautions 4. CONNECT VSC ACTUATOR CONNECTOR (a) Connect the VSC actuator connector. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding Up to 11/2009 Brake Fluid Solenoid Valve Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8357 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 7619 Cabin Temperature Sensor / Switch: Service and Repair Removal AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE ROOM TEMPERATURE SENSOR Specifications Fluid Pan: Specifications AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY Install a new gasket and the oil pan with the 20 bolts. Torque.................................................................................................................................................. .....................................7.0 Nm (71 kgf-cm, 62 in-lbf) Page 2666 Radiator: Service and Repair Installation 1UR-FE COOLING: RADIATOR: INSTALLATION 1. INSTALL RADIATOR ASSEMBLY (a) Install a new O-ring to the drain cock plug. (b) Install the drain cock plug. (c) Install the outlet radiator hose into the radiator. HINT Install the hose so that the direction of the hose clamp is as indicated in the illustration. (d) Set the radiator bracket hooks to the radiator support holes. (e) Install the radiator with the 4 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) 2. INSTALL RADIATOR SIDE DEFLECTOR LH (a) Install the deflector with the 6 clips. (b) Connect the wire harness clamp. 3. INSTALL RADIATOR SIDE DEFLECTOR RH (a) Install the deflector with the 6 clips. ACC Cut Relay Power Distribution Relay: Testing and Inspection ACC Cut Relay 1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION 1. REMOVE ACC CUT RELAY (a) Remove the clip. (b) Detach the 2 clips and remove the cowl side trim board RH. (c) Remove the relay. 2. INSPECT ACC CUT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL ACC CUT RELAY (a) Install the relay. (b) Attach the 2 clips to install the cowl side trim board RH. (c) Install the clip. Page 768 (1) Keep the vehicle stationary on a level surface for 1 second or more. HINT * The zero point calibration is performed only once after the system enters test mode. * Calibration cannot be performed again until the stored data is cleared once. (2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased. (3) Turn the ignition switch off. 6. PERFORM INITIALIZATION OF STEERING ANGLE SENSOR NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will become misaligned. (a) Check that the steering wheel is in the centered position. (b) Disconnect the negative battery terminal for more than 2 seconds. NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. (c) Reconnect the negative battery terminal. Page 6941 J/B No.4 - Instrument Panel Center Page 8258 (a) Attach the 7 clips to install the quarter trim panel. (b) Twist the seat belt clockwise and install the seat belt anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) HINT For the RH side, twist the seat belt counterclockwise. (c) Attach the 2 claws to install the cover. 3. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP 7. INSTALL FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 8. INSTALL FRONT SEAT ASSEMBLY (a) for Manual Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. (b) for Power Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. Page 6142 Auxiliary Power Outlet: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 5039 Reassembly DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): REASSEMBLY 1. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER (for Regular Cab Standard Deck) (a) Install the dynamic and washer damper with the bolt. Torque : 17 Nm (168 kgf-cm, 12 ft-lbf) 2. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR (a) Using SST, a press and steel plate, press in the dust deflector. SST : 09523-36010 NOTICE: Be careful not to damage the dust deflector. 3. INSTALL DIFFERENTIAL CASE ASSEMBLY (a) Install the 2 side gear thrust washers to the side gears. (b) Install the 2 side gears with the thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft. HINT Page 3325 Page 6917 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 5056 (b) Using a press, press out the drive pinion. NOTICE: Do not drop the drive pinion. 12. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING (a) Remove the bearing (inner race) from the differential carrier. 13. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR (a) Remove the 2 bolts and oil deflector. 14. REMOVE FRONT DIFFERENTIAL UNION (a) Remove the front differential union from the differential carrier. 15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST and a press, press out the bearing (inner race). SST : 09950-00020 Page 5748 * Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). * This torque value is effective when union nut wrench is parallel to the torque wrench. 3. CONNECT REAR NO. 1 BRAKE TUBE (a) Using a union nut wrench, connect the brake tube (labeled B) to the brake master cylinder. without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) with union nut wrench - Torque : 18 Nm (186 kgf-cm, 13 ft-lbf) * Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). * This torque value is effective when union nut wrench is parallel to the torque wrench. 4. CONNECT BRAKE FLUID LEVEL WARNING SWITCH CONNECTOR (a) Connect the brake fluid level warning switch connector. 5. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding Front Seat Inner Belt Assembly Seat Belt: Testing and Inspection Front Seat Inner Belt Assembly SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: INSPECTION 1. INSPECT FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: * If the result is not as specified, replace the inner belt assembly. Page 8638 (a) Remove the 4 bolts. (b) Detach the clip and 2 claws, and remove the bracket. Installation AUDIO / VISUAL: TELEVISION DISPLAY: INSTALLATION 1. INSTALL TELEVISION DISPLAY BRACKET Page 5079 (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the bearing retainer as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent HINT Install the differential tube within 10 minutes of applying seal packing. (d) Install the differential tube onto the bearing retainer. (e) Clean the threads of 4 new bolts and the retainer bolt holes with toluene or trichloroethylene. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (g) Install the 4 bolts. Torque : 65 Nm (663 kgf-cm, 48 ft-lb for less) NOTICE: Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration. 45. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator. (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the differential tube as shown in the illustration. Page 4906 Page 9012 "Case2" 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 Fog/Driving Lamp Relay: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 7584 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 2939 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Components Cellular Phone Microphone: Service and Repair Components AUDIO / VISUAL: MICROPHONE AMPLIFIER: COMPONENTS Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2205 Tire Pressure Sensor: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL 1. REMOVE TIRE 2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Remove the valve core and cap, and release the air from the tire. (b) After ensuring that a sufficient amount of air has been released, remove the nut and washer that is used to secure the tire pressure warning valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire. HINT Keep the removed cap, valve core, nut and washer. (c) Disengage the bead using the shoe of a tire remover. NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due to interference between the sensor and tire bead. (d) Remove the bead on the upper side. (e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on the lower side. HINT * The grommet is a non-reusable part. * Check that there are no cracks or damage on the grommet. If any damage is found, replace the washer and nut. Page 6515 Page 6597 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 7700 (b) Disconnect the connector and remove the panel. 16. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift Type)/Removal 17. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift Type)/Removal 18. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System) See: Accessories and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Column Shift Type)/Removal Installation AIR CONDITIONING: AIR CONDITIONING PANEL (for Column Shift Type): INSTALLATION 1. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System) See: Accessories and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Column Shift Type)/Installation 2. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift Type)/Installation 3. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift Type)/Installation 4. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (a) Connect the connector. (b) Attach the 4 clips to install the panel. 5. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation Locations Transmission Speed Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 3790 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 1856 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 3321 Engine Control Module: Pinout Values and Diagnostic Parameters 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM 1. CHECK ECM (a) Measure the voltage according to the value(s) in the table below. HINT The standard voltage between each pair of ECM terminals is shown in the table below. The appropriate conditions for checking each pair of terminals are also indicated. The result of checks should be compared with the standard voltage for that pair of terminals, displayed in the Specified Condition column. The illustration above can be used as a reference to identify the ECM terminal locations. Page 109 Brake Fluid Solenoid Valve Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 3499 Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (ECM) OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR 23. CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER) (a) Disconnect the J19 air conditioning amplifier connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING AMPLIFIER (CANH, CANL) OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY 24. CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU) (a) Disconnect the J59 bus buffer ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+, CAN-) Components Engine Control Module: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS Page 1693 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 1384 Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for Regular Cab) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): ON-VEHICLE INSPECTION 1. CHECK SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the side airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 6303 Driver Side J/B Inner Circuit Page 3227 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 9165 1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from front to back using the pry bar to assist. Be careful NOT to damage the chrome/painted surface. 2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and hammer to punch the plastic bits into the tube. Use an air gun to blow the posts out through the end of the tube. 3. Discard the step pad. 4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard. 5. Install the new post retainers into the holes in the tube. 6. Line up the replacement step posts with the holes in the post retainers. 7. Using the palm of your hand push firmly down in all post locations. Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly. Page 7998 When removing the steering pad, do not pull the airbag wire harness. (c) Disconnect the 2 connectors and remove the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. Installation SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: INSTALLATION 1. INSTALL STEERING PAD (w/ Steering Pad Switch) (a) Support the steering pad with one hand. (b) Connect the 2 connectors to the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Confirm that the circumference groove of the screw fits in the screw case, and place the steering pad onto the steering wheel. (d) Using a T30 "TORX" socket wrench, tighten the 2 screws. Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf) 2. INSTALL STEERING PAD (w/o Steering Pad Switch) (a) Support the steering pad with one hand. (b) Connect the 2 connectors to the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Confirm that the circumference groove of the screw fits in the screw case, and place the steering pad onto the steering wheel. (d) Using a T30 "TORX" socket wrench, tighten the 2 screws. Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf) 3. INSTALL LOWER NO. 3 STEERING WHEEL COVER (a) Attach the 2 claws to install the cover. Page 4113 (3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. (4) Pinch the connector and disconnect the connector and pipe. (5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out. NOTICE: Do not use any tools. (6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. (7) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag. (e) Observe these precautions when connecting the fuel tube connector (for Quick Type). (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe. (3) After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected. Page 1881 (g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap. NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap. (h) Install the oil filter drain plug. Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Be careful that the O-ring does not get caught between any surrounding parts. 5. ADD ENGINE OIL (a) Add fresh oil. Standard Oil Grade (for USA): Standard Oil Grade (for Canada): Standard Oil Capacity: (b) Install the oil filler cap. 6. INSPECT FOR OIL LEAK (a) Start the engine. Make sure that there are no oil leaks from the area that was worked on. 7. CHECK ENGINE OIL LEVEL See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Testing and Inspection 8. INSTALL NO. 1 ENGINE UNDER COVER Page 5503 Control Module: Diagrams Page 1874 Repair Procedure Page 9395 10. Lower the cab back onto the No. 3 cab mount. 11. Install the new bolt through the No.3 cab mount and install the large washer and NEW nut and torque to specifications. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) 12. Torque the nuts to the specified torque range on the No.2 mounts. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) Page 8853 3. INSTALL REAR DOOR ARMREST COVER LH 4. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 5. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 6. INSTALL REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Reassembly 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Locations Trailer Towing Relay: Locations Engine Room R/B, J/B - Engine Compartment Left Locations Transmission Mode Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 6274 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 7315 (a) Using a clip remover, remove the 5 clips and apron seal. 7. REMOVE FRONT SUSPENSION UPPER ARM ASSEMBLY (a) Remove the nut, bolt, 2 washers and suspension upper arm. Installation SUSPENSION: FRONT UPPER SUSPENSION ARM: INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. TEMPORARILY INSTALL FRONT SUSPENSION UPPER ARM ASSEMBLY LH (a) Temporarily install the suspension upper arm with the 2 washers, bolt and nut. HINT After stabilizing the suspension, tighten the nut. 2. INSTALL FRONT FENDER APRON SEAL REAR LH (a) Install the apron seal with the 5 clips. 3. INSTALL FRONT FENDER APRON SEAL LH (a) Install the apron seal with the 6 clips. 4. CONNECT STEERING KNUCKLE LH (a) Connect the steering knuckle to the suspension upper arm. (b) Install the nut and a new cotter pin. Torque : 110 Nm (1122 kgf-cm, 81 ft-lbf) Page 6442 Power Distribution Module: Service and Repair Removal OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 6. REMOVE VOLTAGE INVERTER ASSEMBLY (a) Remove the 2 bolts. (b) Disconnect the voltage inverter connector and removal the voltage inverter. Page 2755 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Transponder Key ECU Alarm Module: Diagrams Transponder Key ECU Page 3368 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 4282 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 616 Parking Assist Switch: Service and Repair Installation PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSTALLATION 1. INSTALL DRIVE MONITOR SWITCH (a) Attach the 2 claws to install the monitor switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 6085 Neutral Safety Switch: Adjustments A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT 1. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Loosen the bolt of the park/neutral position switch and move the shift lever to N. (b) Align the groove with the neutral basic line. (c) Hold the switch in position and tighten the bolt. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (d) After the adjustment, perform the on-vehicle inspection See: Testing and Inspection/Initial Inspection and Diagnostic Overview. Bleeding Brake Bleeding: Service and Repair Bleeding BRAKE: BRAKE FLUID: BLEEDING NOTICE: * Perform fluid replacement with the parking brake applied. * Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir. * Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off immediately. * After adding brake fluid, make sure the reservoir is sufficiently full. * When bleeding air, select the suitable procedure listed below. 1. BLEED BRAKE LINE (a) Bleed brake line (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (7) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. (10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (13)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (b) Check and bleed brake system. (1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform the following air bleed procedures. Page 7293 09951-00180 09951-00320 09952-06010 SST : 09950-70010 09951-07150 (c) Using SST and a press, install the control valve upper bearing. SST : 09950-60010 09951-00180 09951-00340 09952-06010 SST : 09950-70010 09951-07150 8. INSTALL POWER STEERING CONTROL VALVE ASSEMBLY (a) Expand 4 new control valve rings with your fingers. NOTICE: Be careful not to over expand the control valve rings. (b) Coat the 4 control valve rings with power steering fluid. (c) Install the 4 control valve rings onto the control valve, and position them with your fingers. (d) Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve. Page 4044 Air Injection Pump: Service and Repair Installation 1UR-FE EMISSION CONTROL: AIR PUMP: INSTALLATION 1. INSTALL AIR PUMP ASSEMBLY (a) Connect the 6 air pump insulators to the air pump and install the air pump to the bracket. (b) Attach the 2 wire harness clamps to the bracket. 2. CONNECT NO. 1 AIR INJECTION SYSTEM HOSE (a) Connect the 2 No. 1 air injection system hoses to the air pump. HINT Insert the hoses until the hose ends are aligned with the stoppers. 3. INSTALL AIR PUMP INLET (a) Connect the air pump inlet to the No. 1 air injection system hoses to install it, and then slide the 2 clips onto the hoses. HINT Insert the inlet until the inlet stoppers are aligned with the hose ends. (b) Install the 2 bolts. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) 4. INSTALL AIR PUMP ASSEMBLY WITH BRACKET (a) Install the air pump to the vehicle. Page 2749 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 2656 Engine Temperature Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Coolant/Service and Repair 4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm ball joint lock nut wrench, remove the sensor. (c) Remove the gasket from the sensor. Diagram Information and Instructions Relay Box: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 6185 HINT Tape the screwdriver tip before use. 7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. Page 2099 Driver Side J/B Inner Circuit Page 8111 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 6. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 8. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched Page 8858 Accessory Relay: Diagrams Page 3564 10. CHECK COMBINATION METER ECU (a) Disconnect the J28 ECU connector. (b) Measure the resistance according to the value(s) in the table below. HINT * *1: for V bus * *2: for MS bus 11. CHECK STEERING ANGLE SENSOR (a) Disconnect the J6 sensor connector. Page 3170 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Up to 11/2009 Brake Fluid Pump Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 3443 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU) OK -- Continue to next step. 9. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A46 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Page 199 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 8534 11. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 1958 Refrigerant Oil: Fluid Type Specifications COMPRESSOR OIL Type...................................................................................................................................................... ..............................................ND-OIL 8 or equivalent Page 3243 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Heated Oxygen Sensor Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE INSPECTION 1. CHECK HEATED OXYGEN SENSOR (a) Disconnect the heated oxygen sensor connector. (b) Measure the heater resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the heated oxygen sensor. (d) Connect the heated oxygen sensor connector. Page 4407 Installation Procedure 1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover (2 places). 2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1 place). Locations Manifold Pressure/Vacuum Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Diagrams Variable Valve Timing Actuator Position Sensor: Diagrams Page 602 HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the front bumper. Installation PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): INSTALLATION 1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the front bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 2. INSTALL NO. 1 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. Page 6531 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 2022 Page 8454 Alarm Module: Locations Theft Deterrent System THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 3133 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 4920 8. INSTALL COLUMN SHIFT LEVER COMPRESSION SPRING (a) Apply MP grease to the spring as shown in the illustration. (b) Temporarily install the spring to the column shift control shift lever retainer with the bolt. (c) With the shift lever protrusion pushed towards the N position wall of the control shift lever retainer, align the spring roller with the groove as shown in the illustration. Then tighten the bolt. Torque : 3.8 Nm (38 kgf-cm, 33 in-lbf) 9. INSTALL COLUMN SHIFT SHIFTING BELLCRANK ASSEMBLY Page 2629 Water Pump: Service and Repair Installation 1UR-FE COOLING: WATER PUMP: INSTALLATION 1. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and the water pump with the 8 bolts shown in the illustration. for bolt A - Torque : 47 Nm (479 kgf-cm, 35 ft-lbf) for bolt B - Torque : 23 Nm (235 kgf-cm, 17 ft-lbf) for bolt C - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) 2. INSTALL WATER PUMP PULLEY (a) Temporarily install the pulley with the 4 bolts. (b) Using SST, hold the pulley and tighten the 4 bolts. SST : 09960-10010 09962-01000 09963-01000 Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 3. INSTALL WATER INLET HOUSING (a) Install a new gasket to the water pump. (b) Install the water inlet housing with the 3 bolts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 4. CONNECT NO. 5 WATER BY-PASS HOSE (a) Connect the water by-pass hose. Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 5942 Page 9177 Installation EXTERIOR: SIDE STEP: INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. INSTALL SIDE STEP ASSEMBLY (a) Install the side step with the 8 bolts. Torque : 19.5 Nm (199 kgf-cm, 14 ft-lbf) Page 4924 Page 4736 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Components Remote Switch: Service and Repair Components AUDIO / VISUAL: STEERING PAD SWITCH: COMPONENTS Page 9100 Page 729 Seat Heater Switch: Locations Seat Heater System SEAT: SEAT HEATER SYSTEM: PARTS LOCATION Page 7547 12. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 13. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 14. CHECK PARKING BRAKE INSTALLATION See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 15. INSTALL REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Installation 16. ADJUST PARKING BRAKE SHOE CLEARANCE See: Brakes and Traction Control/Parking Brake System/Adjustments 17. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 18. INSTALL REAR WHEEL LH for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 19. CHECK PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake System/Adjustments 20. ADJUST PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake System/Adjustments Page 8848 (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 3 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 3. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Reassembly 4. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Reassembly 5. INSTALL REAR DOOR ARMREST COVER LH 6. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Reassembly 7. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Reassembly 8. INSTALL REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for CrewMax)/Reassembly 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Up to 11/2009 AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): COMPONENTS Page 1912 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type ..................................................................................................................................................... ......................................... Toyota Genuine ATF WS Notice: Using automatic transmission fluid other than "Toyota Genuine ATF WS" may cause deterioration in shift quality, locking up of your transmission accompanied by vibration, and ultimately damage the automatic transmission of your vehicle. Page 808 Page 3823 Manifold Pressure/Vacuum Sensor: Diagrams Page 5506 Control Module: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE 4WD CONTROL ECU (a) Disconnect the 2 ECU connectors. (b) Remove the bolt and ECU. Page 3424 NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (CENTER AIRBAG SENSOR) OK -- REPLACE CENTER AIRBAG SENSOR 12. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU) NOTICE: For vehicles without 4WD, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU)". (a) Disconnect the A25 4WD control ECU connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU) A -Continue to next step. 13. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (4WD CONTROL ECU) OK -- REPLACE 4WD CONTROL ECU 14. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU) NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE)". (a) Disconnect the J101 power steering ECU connector. Diagrams Shift Interlock Solenoid: Diagrams Body/Frame - Choppy Ride Condition Body / Frame Mount Bushing: Customer Interest Body/Frame - Choppy Ride Condition T-SB-0369-10 December 23, 2010 Choppy Ride (Tundra D-Cab Short Bed) Service Category Suspension Section Rear Suspension Market USA Applicability Introduction Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road conditions. A newly designed cab mount has been developed to help improve this condition. NOTE 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 occurrence of the specified condition described in this bulletin. Page 5764 Page 6576 Accessory Relay: Diagrams Page 5048 16. REMOVE REAR DRIVE PINION NUT (a) Using SST to hold the companion flange, remove the nut. SST : 09330-00021 09330-00030 17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY See: Differential Carrier Assembly/Disassembly 18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST, remove the bearing (inner race). SST : 09556-22010 20. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new spacer onto the drive pinion. Page 4720 Four Wheel Drive Selector Switch: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION 1. INSTALL 4WD CONTROL SWITCH (a) Attach the 3 claws to install the switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 382 (a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE OK -- Continue to next step. 2. INSPECT RELAY (IG2, EFI) (a) Remove the integration relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 6525 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 4673 Control Module: Diagrams Page 6523 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Specifications Alignment: Specifications SERVICE SPECIFICATIONS: SUSPENSION: SERVICE DATA Stanard Vehicle Height for Regular Cab of Standard Deck for Regular Cab of Long Deck for Double Cab of Standard Deck Page 7450 No further tightening is required once the nut is tightened with the specified torque. 2. INSTALL WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 3. INSPECT TIRE (a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics. 4. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration. 5. PERFORM INITIALIZATION (a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 6. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data List / Active Test. Audio and Visual System Remote Switch: Locations Audio and Visual System AUDIO / VISUAL: AUDIO AND VISUAL SYSTEM: PARTS LOCATION Page 3898 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Page 1818 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 5634 Traction Control Switch: Testing and Inspection BRAKE CONTROL: VSC OFF SWITCH: INSPECTION 1. INSPECT VSC OFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the VSC OFF switch. Page 1889 Hose/Line HVAC: Service and Repair From 11/2009 AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS Page 6993 Engine Room R/B, J/B - Engine Compartment Left Page 7762 11. REMOVE AIR CONDITIONING UNIT (a) Remove the nut and air conditioning unit. Installation AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION 1. INSTALL AIR CONDITIONING UNIT ASSEMBLY (a) Install the air conditioning unit with the nut. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) Page 4258 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 5972 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 6483 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 5858 Brake Fluid Pressure Sensor/Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8371 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Page 7061 Standard steering axis inclination (unloaded vehicle): for Regular Cab of Long Deck Standard steering axis inclination (unloaded vehicle): for Double Cab of Standard Deck Page 2920 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 3425 (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result NG -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE) OK -- Continue to next step. 15. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (POWER STEERING ECU) OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal 16. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE) (a) Disconnect the J19 air conditioning amplifier connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Audio System - USB/iPod(R) Not Recognized Auxiliary Input / Output Jack: Customer Interest Audio System - USB/iPod(R) Not Recognized T-SB-0013-11 February 15, 2011 USB/Pod Not Recognized Service Category Audio/Visual/Telematics Section Audio/Video Market USA Applicability Introduction Some 2010 - 2011 Toyota vehicles may exhibit intermittent operation of USB/iPod(TM) devices while in use. A newly designed Multi-Media Interface ECU has been developed to correct this condition. This bulletin applies to the models shown. This bulletin does not apply to the following models: iPod(TM) mini iPod(TM) shuffle iPod(TM) photo iPhone(TM) and 4th generation and earlier models. These versions of the iPod(TM) are NOT compatible with this system. * iPhone(TM) has limited compatibility with this system. Some functions may not operate properly. Production Change Information Page 6199 Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL 1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 2. REMOVE CONSOLE BOX BEZEL Page 4211 Page 9158 1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from front to back using the pry bar to assist. Be careful NOT to damage the chrome/painted surface. 2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and hammer to punch the plastic bits into the tube. Use an air gun to blow the posts out through the end of the tube. 3. Discard the step pad. 4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard. 5. Install the new post retainers into the holes in the tube. 6. Line up the replacement step posts with the holes in the post retainers. 7. Using the palm of your hand push firmly down in all post locations. Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly. Fuel Sender Gauge Assembly Fuel Gauge Sender: Service and Repair Fuel Sender Gauge Assembly Components 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: COMPONENTS Removal 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: REMOVAL 1. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Page 8438 HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL FENDER ANTENNA ASSEMBLY (a) Install the antenna with the bolt. (b) Attach the 5 clamps and install the bolt. (c) Connect the connector. 2. INSTALL FENDER APRON MUDGUARD SEAL RH See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Installation 3. INSTALL ANTENNA ORNAMENT Page 5276 (1) Temporarily install the center support bearing to the crossmember with the 2 mounting bolts. (b) w/ Bearing Washer: (1) Temporarily install the center support bearing to the crossmember with the 2 bearing washers and 2 mounting bolts. (c) Align the matchmarks on the flange yoke and transfer flange. (d) Install the propeller shaft to the transfer side with the 4 nuts. Torque : 70 Nm (714 kgf-cm, 52 ft-lbf) (e) Align the matchmarks on the flange yoke and differential flange. (f) Install the propeller shaft to the differential side with the 4 bolts and 4 nuts. Torque : 70 Nm (714 kgf-cm, 52 ft-lbf) Page 8074 Impact Sensor: Service and Repair Front Airbag Sensor Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 8260 Removal SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for CrewMax): REMOVAL 1. DISCONNECT REAR SEAT INNER BELT ASSEMBLY See: Rear Seat Inner Belt Assembly (for CrewMax)/Removal 2. REMOVE REAR SEAT ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Crewmax LH Side)/Removal 3. DISCONNECT CENTER REAR SEAT OUTER BELT ASSEMBLY Page 3402 CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: HOW TO PROCEED WITH TROUBLESHOOTING HINT * DTCs for the CAN communication system are as follows: U0073, U0100, U0114, U0123, U0124, U0126, U0129, U0199, U0208, U1002, U1115, B1499, and B2621 * Refer to the troubleshooting procedures of each system if DTCs regarding the CAN communication system are not output. * Before measuring the resistance, leave the vehicle for at least 1 minute and do not operate the ignition switch, any switches or doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT * Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. * *: Use the Techstream. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. 3. CHECK AND CLEAR DTC* (a) Using the Techstream, perform the ALL DTC check. NOTICE: * If a CAN communication malfunction code that informs that an ECU or sensor has a power malfunction or interior malfunction is causing a communication stop, the problem may not be in the communication line. There is a high possibility that the ECU or sensor has a signal transmission failure. Therefore, first troubleshoot any DTCs related to the ECU or sensor. * When CAN communication related connectors are disconnected with the ignition switch ON or ACC, the ECU related to the connector and ECUs of related systems will store a CAN communication DTC. NEXT -- Continue to next step. 4. CHECK INSTALLED SYSTEMS (ECU AND SENSOR) THAT USE CAN COMMUNICATION (a) Based on the vehicle equipment and specifications, confirm the systems that use CAN communication See: CAN Communication System/Diagnosis System. NEXT -- Continue to next step. 5. CHECK DLC3 BRANCH WIRE AND V BUS CIRCUIT MAIN WIRE (CANH - CANL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 2060 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 3843 Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION 1. INSPECT AIR FUEL RATIO SENSOR (a) Disconnect the 2 sensor connectors. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the air fuel ratio sensor. (d) Connect the 2 sensor connectors. Page 7773 AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY 1. INSTALL COOLER EXPANSION VALVE (a) Sufficiently apply compressor oil to 4 new O-rings and the fitting surface of the hose joint. Compressor oil: ND-OIL 8 or equivalent (b) Install the 2 O-rings to the cooler evaporator. (c) Install the 2 O-rings to the tube and accessory. (d) Install the cooler expansion valve and tube and accessory to the evaporator. (e) Using a 4 mm hexagon wrench, install the 2 bolts. Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf) 2. INSTALL NO. 1 COOLER THERMISTOR NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted. (a) Insert the sensor to a location that is 1 fin to the right or left of its previous location. Standard: 3. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY Page 6478 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 3849 with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 5. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (b) Connect the air fuel ratio sensor connector. (c) Connect the heated oxygen sensor connector and 2 clamps. 6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Page 1678 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 7922 (b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat with a new one: Cuts, minute cracks or marked discoloration on the front seatback around the front seat side airbag. 2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat side airbag with a new one: * Cuts, minute cracks or marked discoloration on the front seat side airbag. * Cracks or other damage to the wire harness or connector. CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow the correct procedure. Front Passenger Side Knee Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY: ON-VEHICLE INSPECTION 1. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the lower No. 2 instrument panel airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the lower No. 2 instrument panel airbag with a new one: Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag. 2. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 202 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 6688 Page 7931 Cross-sectional area of stripped wire harness section: 1.25 mm2 or more (0.00192 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the lower No. 2 instrument panel airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with a cross-sectional area of at least 1.25 mm2 (0.00192 in.2). HINT To calculate the cross-sectional area of the stripped wire harness section: Cross-sectional area = 3.14 x (Diameter)2 / 4 (1) Position the lower No. 2 instrument panel airbag inside a tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions Width 185 mm (7.28 in.) Inner diameter 360 mm (14.2 in.) (2) Tie the lower No. 2 instrument panel airbag to the tire with several wire harnesses. CAUTION: * Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the lower No. 2 instrument panel airbag may become loose due to the shock when the airbag is deployed. * Always tie down the lower No. 2 instrument panel airbag with the airbag deployment side facing inside the tire. NOTICE: As the tire may be damaged by the airbag deployment, use a tire that you are planning to throw away. (d) Connect SST connector to the lower No. 2 instrument panel airbag. SST : 09082-00780 (e) Place tires. Page 8785 (b) If the result is not as specified, replace the speaker assembly. Page 3691 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 1086 Headlamp Alignment Switch: Service and Repair Installation LIGHTING: HEADLIGHT LEVELING SWITCH: INSTALLATION 1. INSTALL HEADLIGHT LEVELING SWITCH (a) Attach the 2 claws to install the switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 7318 (a) Remove the nut and bolt, and disconnect the shock absorber from the lower side. 4. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH (a) Remove the 2 bolts and disconnect the attachment from the steering knuckle. 5. REMOVE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH (a) Place matchmarks on the No. 2 camber adjusting cam and No. 2 toe adjusting plate. (b) Remove the nut, washer, No. 2 camber adjusting cam, camber adjusting cam assembly, bolt, toe adjusting cam, No. 2 toe adjusting plate and front No. 1 suspension arm lower LH. 6. REMOVE FRONT LOWER BALL JOINT ATTACHMENT LH (a) Remove the cotter pin and nut. (b) Using SST, remove the lower ball joint attachment. Removal and Replacement Starter Motor: Removal and Replacement Components 1UR-FE STARTING: STARTER (for 1.6 kW Type): COMPONENTS Removal 1UR-FE STARTING: STARTER (for 1.6 kW Type): REMOVAL 1. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Testing and Inspection Stabilizer Link: Testing and Inspection SUSPENSION: FRONT STABILIZER BAR: INSPECTION 1. INSPECT FRONT STABILIZER LINK ASSEMBLY LH (a) Temporarily install the nut, and flip the ball joint stud back and forth 5 times as shown in the illustration. (b) Use a torque wrench to turn the nut continuously at a rate of 2 to 3 seconds per turn. Take the torque reading on the fifth turn. Standard turning torque - Torque : 0.5 to 3.4 Nm (5.1 to 36 kgf-cm, 4.4 to 30 in-lbf) * If the value is not within the specified range, replace the front suspension toe control link with a new one. (c) Check the dust boot for cracks or grease leakage. Page 2357 Step 2: Mark the front of the bearing cap bolts with paint. Tighten the bearing cap bolts another 90° in the order shown in step 1. Check that the painted marks are now at a 90° angle to the front. Install and uniformly tighten the 10 main bearing cross cap bolts and 10 new seal washers in several steps, in the sequence shown in the illustration. Torque.................................................................................................................................................. .....................................45 Nm (459 kgf-cm, 33 ft-lbf) MAIN BEARING SIZE CODES Refer to the table below for the appropriate bearing number. There are 6 sizes of standard bearings. For the No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 and 9. For other bearings, use bearings marked 3, 4, 5, 6, 7 and 8. A = Cylinder block number mark B = Crankshaft number mark Page 8462 (a) Disconnect the connectors. (b) Remove the 2 nuts and junction block. (c) Remove the nut and ECU. Page 2765 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 1482 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 7930 (2) Install the lower No. 2 instrument panel airbag See: Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation. NOTICE: Take care not to damage SST wire harness. (3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window. (4) Maintaining enough clearance for SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage SST wire harness. (5) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle. (2) Press SST activation switch to deploy the airbag. CAUTION: * When deploying the airbag, make sure that no one is near the vehicle. * The lower No. 2 instrument panel airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag with a deployed airbag. * Do not apply water to a lower No. 2 instrument panel airbag with a deployed airbag. * Always wash your hands with water after completing the operation. HINT The airbag is deployed as the LED of SST activation switch comes on. 2. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: Be sure to follow the procedure detailed below when deploying the airbag. HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Remove the lower No. 2 instrument panel airbag See: Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal. CAUTION: * When removing the lower No. 2 instrument panel airbag, wait at least 90 seconds after the ignition switch is turned off and the cable is disconnected from the negative (-) battery terminal before starting work. * When storing the lower No. 2 instrument panel airbag, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the lower No. 2 instrument panel airbag to a tire. Locations Ignition Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 2489 Front Crankshaft Seal: Service and Repair Removal 1UR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and Repair/Replacement 3. DRAIN ENGINE COOLANT See: Cooling System/Coolant/Service and Repair 4. REMOVE INLET RADIATOR HOSE See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal 5. REMOVE FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 6. REMOVE FAN SHROUD See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal 7. DISCONNECT FRONT STABILIZER BAR (a) Remove the 4 bolts, 2 stabilizer brackets and 2 stabilizer bushes. Then disconnect the stabilizer bar. 8. DISCONNECT COOLER COMPRESSOR ASSEMBLY See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Removal 9. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY See: Engine Lubrication/Oil Pressure Sender/Service and Repair/Removal 10. REMOVE WATER BY-PASS PIPE (w/ Oil Cooler) See: Water Pump/Service and Repair/Removal 11. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See: Engine Lubrication/Oil Cooler/Service and Repair/Removal and Replacement/Removal 12. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY See: Engine Lubrication/Oil Cooler/Service and Repair/Removal and Replacement/Removal 13. REMOVE CRANKSHAFT PULLEY See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Removal 14. REMOVE CRANKSHAFT TIMING GEAR KEY (a) Remove the crankshaft timing gear key from the crankshaft. 15. REMOVE FRONT CRANKSHAFT OIL SEAL (a) Using a screwdriver, pry out the oil seal. Page 9324 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 1669 Wiper Switch: Service and Repair Removal WIPER AND WASHER: WIPER SWITCH: REMOVAL 1. REMOVE LOWER STEERING COLUMN COVER (a) for Manual Tilt and Telescopic: (1) Operate the tilt and telescopic lever to fully extend and lower the steering column. (b) for Power Tilt and Telescopic: (1) Turn the ignition switch ON. Operate the tilt and telescopic switch to fully extend and lower the steering column. (c) While turning the steering wheel to the right and left, remove the 2 screws and lower steering column cover. (d) Detach the 2 claws to remove the lower steering column cover. NOTICE: Do not damage the tilt and telescopic switch. 2. REMOVE UPPER STEERING COLUMN COVER (a) Detach the 4 clips. (b) Detach the claw to remove the upper steering column cover. 3. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (a) Disconnect the 2 connectors. Page 6490 Relay Box: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 3560 HINT * *1: w/ 4WD * *2: w/ Bus Buffer ECU (c) NO. 3 JUNCTION CONNECTOR HINT * *1: for MS bus * *2: w/ Seat Memory 3. TERMINALS OF CONNECTORS FOR JUNCTION CONNECTOR (No. 1 JUNCTION CONNECTOR) Page 9112 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Airbag Cut-OFF Switch Air Bag Deactivation Switch: Testing and Inspection Airbag Cut-OFF Switch SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSPECTION 1. INSPECT AIRBAG CUT-OFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 5899 Traction Control Switch: Service and Repair Installation BRAKE CONTROL: VSC OFF SWITCH: INSTALLATION 1. INSTALL VSC OFF SWITCH (a) Attach the 2 claws to install the VSC OFF switch into the lower instrument panel finish panel LH. (b) Connect the VSC OFF switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 7076 Page 1764 (4) Connect the engine wire harness clamp. 3. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts. Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Tighten the hose clamp. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) (c) Connect the ventilation hose and vacuum hose. (d) Connect the MAF meter connector and clamp. 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 2876 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY (a) Connect the 3 connectors. (b) Install the integration relay to the engine room relay block. (c) Install the engine room relay block cover. Page 6410 Page 8781 Speaker: Testing and Inspection Floor Speaker (for Double Cab) AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSPECTION 1. INSPECT BOX SPEAKER ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Page 4895 Standard Resistance: (c) If the result is not as specified, replace the transmission floor shift assembly. Related Testing (Shift Lever Diagnostics) For information regarding additional/related testing for this system, please refer to Transmission Control System testing. See: Transmission Control Systems/Testing and Inspection Page 6656 Installation OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): INSTALLATION 1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply) (a) Attach the 2 claws to install the power outlet socket. 2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard) (a) Attach the 2 claws to install the power outlet socket cover. 3. INSTALL REAR POWER OUTLET SOCKET (for Standard) (a) Attach the claw to install the power outlet socket. 4. INSTALL CONSOLE BOX BEZEL Diagram Information and Instructions Information Bus: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 1039 Cargo Lamp Switch: Testing and Inspection LIGHTING: CARGO LIGHT SWITCH: INSPECTION 1. INSPECT CARGO LIGHT SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. (c) Inspect the switch illumination. (1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 4 (ILL-). (2) Check that the door courtesy light comes on. OK: Light comes on. (3) If the result is not as specified, replace the light switch. Page 583 Integrated Accessory Switch Assembly: Diagrams Page 204 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 1866 * Never reuse the O-ring. * When placing a new O-ring on the injector, do not damage it. * Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and intake manifold as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type). (1) for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration. (2) for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector. Page 6222 Auxiliary Power Outlet Switch: Service and Repair Installation OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION 1. INSTALL INVERTER MAIN SWITCH (a) Attach the 2 claws to install the main switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Locations Variable Induction Control Solenoid: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Engine - Oil Filter Cap Assembly Precaution Oil Filter: Technical Service Bulletins Engine - Oil Filter Cap Assembly Precaution T-SB-01 04-09 April 10, 2009 Oil Filter Cap Assembly Precautions Service Category Engine/Hybrid System Section Lubrication Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. T-SB-0332-08. ^ Applicability has been updated to include 2009 - 2010 model year Highlander, 2010 model year Camry, Corolla, Matrix, Sequoia, Tundra, and 2009 model year Venza vehicles. ^ The SST table has been updated with an illustration. ^ The Notice in the Repair Procedure has been updated with a Figure and torque specification ranges to clarify SST usage. TSB No. T-SB-0332-08 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction To prevent damage to the oil filter cap assembly this procedure must be closely followed during oil filter replacement to avoid immediate and future oil filter serviceability concerns. The following engines are equipped with a plastic oil filter cap assembly: ^ 1UR-FE (Tundra Sequoia) ^ 3UR-FE (Tundra Sequoia Land Cruiser) ^ 2ZR-FE (Corolla Matrix) Page 3463 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 5949 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Door Control Receiver (for CrewMax) Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax) Components DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS Removal DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal Page 267 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 1410 (b) Loosen the nut, move the stay off the battery, and remove the battery. 3. REMOVE FRONT AIRBAG SENSOR (a) Remove the nut and front airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Connect the connector. (d) Install the front airbag sensor with the nut. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the front airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (e) Check that there is no looseness in the installation parts of the front airbag sensor. 2. INSTALL BATTERY Page 6728 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 5489 Page 6273 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 3683 ^ 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 6149 "Case2" 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 7505 Tire Pressure Warning Reset Switch: Testing and Inspection TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION 1. CHECK TIRE PRESSURE WARNING RESET SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Specifications Water Pump: Specifications WATER PUMP ASSEMBLY Install a new gasket and the water pump with the 8 bolts shown in the illustration. For bolt A - Torque............................................................................................................................... ....................................47 Nm (479 kgf-cm, 35 ft-lbf) For bolt B - Torque............................................................................................................................... ....................................23 Nm (235 kgf-cm, 17 ft-lbf) For bolt C - Torque............................................................................................................................... ....................................20 Nm (204 kgf-cm, 15 ft-lbf) Page 6458 Page 4045 (1) Insert the bracket tab into the slot and insert the stud bolt into the bracket hole as shown in illustration A. Then slide the bracket. (2) Insert the bracket tab into the slot shown in illustration B. (3) Install the 2 bolts and 2 nuts. for bolt - Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) for nut - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) (b) Connect the 2 air pump connectors and attach the 3 wire harness claws. 5. INSTALL NO. 3 AIR INJECTION SYSTEM HOSE (a) Connect the No. 3 air injection system hose so that its paint mark aligns with the air pump's rib as shown in the illustration below labeled A. (b) Connect the clamp to the No. 3 air injection system hose shown in the illustration below labeled B. Then insert the clamp's clip into the body hole. HINT Align the paint mark of the No. 3 air injection system hose with the edge of the clamp. (c) Connect the No. 3 air injection system hose to the air tube shown in the illustration below labeled C. HINT * Make sure the paint mark of the No. 3 air injection system hose is facing upward. * Make sure the direction of the hose clamp is as shown in the illustration. (d) Connect the clamp to the No. 3 air injection system hose and wire harness shown in the illustration below labeled D. Then insert the clamp's clip into the body hole. HINT Align the paint mark of the No. 3 air injection system hose and paint mark of the wire harness with the edge of the clamp. 6. INSTALL NO. 2 AIR INJECTION SYSTEM HOSE (a) Connect the No. 2 air injection system hose so that its paint mark aligns with the air pump's rib as shown in the illustration below labeled E. (b) Connect the No. 2 air injection system hose to the air tube shown in the illustration below labeled F. HINT * Make sure the paint mark of the No. 2 air injection system hose is facing upward. * Make sure the direction of the hose clamp is as shown in the illustration. (c) Connect the white colored clamp to the No. 2 air injection system hose and wire harness shown in the illustration below labeled G. HINT Page 3100 Ignition Switch: Service and Repair Removal 1UR-FE STARTING: IGNITION SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal. (b) for Manual Tilt and Manual Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal. (c) for Power Tilt and Power Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal. 3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Disassembly 4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly 5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly 6. REMOVE IGNITION SWITCH ASSEMBLY (a) Detach the 2 claws and remove the ignition switch from the steering lock. Page 886 Oil Pressure Sender: Service and Repair Removal 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Disconnect the sender gauge connector. (b) Remove the oil pressure sender gauge. Locations Gear Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 4788 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 7321 (a) Tighten the nut. Torque : 195 Nm (1988 kgf-cm, 144 ft-lbf) 8. INSTALL FRONT WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 9. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair. Page 9082 Trailer Towing Part 4 Component Tests and General Diagnostics Steering Angle Sensor: Component Tests and General Diagnostics BRAKE CONTROL: STEERING ANGLE SENSOR: INSPECTION 1. CHECK STEERING ANGLE SENSOR (a) Check the steering angle sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 2396 Engine Oil: Service and Repair Replacement 1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT CAUTION: * Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. * Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents. * In order to protect the environment, used oil and used oil filters must be disposed of at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container. (c) Install a new gasket and the oil pan drain plug. Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) 2. REMOVE NO. 1 ENGINE UNDER COVER (a) Remove the 3 screws and 5 bolts. (b) Unhook the engine under cover from the vehicle body as shown in the illustration. 3. REMOVE OIL FILTER ELEMENT (a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe. Page 8800 Removal AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly Audio and Visual System Remote Switch: Locations Audio and Visual System AUDIO / VISUAL: AUDIO AND VISUAL SYSTEM: PARTS LOCATION Page 7545 Wheel Fastener: Service and Repair Rear Axle Hub Bolt Components AXLE: REAR AXLE HUB BOLT: COMPONENTS Replacement AXLE: REAR AXLE HUB BOLT: REPLACEMENT HINT * Use the same procedures for the LH side and RH side. Page 2009 Push the terminal retainer down to the temporary lock position. Page 4713 Four Wheel Drive Selector Switch: Diagrams Page 4748 ^ 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 5092 5. Replace the affected oil baffle. A. Using a double nut configuration remove 2 axle housing stud bolts to allow the oil baffle to be removed. See Figures 3 and 4 and attached video below for reference. B. Use a 10 mm 1.25 thread chaser or cleaner to carefully clean the axle housing threads. NOTICE After cleaning the axle housing threads be sure to thoroughly clean out the axle housing of any debris to prevent damage to the differential assembly. C. Replace the oil baffle and fully seat the new baffle against the upper and lower tabs. See Figure 5 for reference. D. Using a double nut configuration install the new axle housing stud bolts until they are fully seated. Torque: 36 N*m (373 kgf*cm, 27 ft*lbf) 6. Install the rear differential and axle shafts. Take special care not to damage the oil baffle or axle seals when installing the axle shaft assembly. Refer to TIS applicable model year Tundra Repair Manual: 7. Test drive the vehicle and confirm proper operation. Page 6395 Page 5441 Four Wheel Drive Selector Switch: Diagrams Page 3318 Standard Voltage: NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) OK -- REPLACE ECM See: Service and Repair/Removal 5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the ignition switch connector. (c) Disconnect the cable from the battery positive (+) terminal. (d) Remove the AM2 fuse and integration relay. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 8787 (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 12 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Front Door Speaker (for Double Cab) AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSPECTION Page 2739 Page 6443 Power Distribution Module: Service and Repair Installation OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION 1. INSTALL VOLTAGE INVERTER ASSEMBLY (a) Connect the voltage inverter connector. (b) Install the voltage inverter with the 2 bolts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 4308 ^ 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 4280 ^ 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. Air Conditioning System (for Automatic Air Conditioning System) Compressor Speed Sensor: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Locations Power Distribution Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 6315 AJ1-AJ8 Page 4606 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 7564 Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: REMOVAL 1. REMOVE AMBIENT TEMPERATURE SENSOR (a) Disconnect the connector. (b) Using a screwdriver, detach the clamp and remove the ambient temperature sensor. HINT Tape the screwdriver tip before use. Page 5804 Vacuum Brake Booster: Service and Repair Installation BRAKE: BRAKE BOOSTER: INSTALLATION 1. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY 2. INSTALL BRAKE BOOSTER ASSEMBLY (a) Install the clevis. (b) Install a new brake booster gasket to the brake booster. (c) Install the brake booster with the 4 nuts. Torque : 15 Nm (155 kgf-cm, 11 ft-lbf) 3. INSTALL PUSH ROD PIN See: Brake Pedal Assy/Service and Repair/Installation 4. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 8. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. CONNECT BRAKE BOOSTER CONNECTOR (a) Connect the 2 brake booster connectors to the brake booster. 10. CONNECT VACUUM HOSE ASSEMBLY (a) Connect the vacuum hose onto the check valve. NOTICE: Do not use lubricant when installing a vacuum hose on the brake booster and check valve sides. 11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (a) Install the brake master cylinder See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Installation. 12. CHECK AND ADJUST BRAKE PEDAL (a) Check and adjust brake pedal See: Brake Pedal Assy/Adjustments. 13. CHECK BRAKE BOOSTER See: Testing and Inspection 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 15. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding Page 3439 B -- REPLACE ECM A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal Short to B+ in CAN Bus Line CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short to B+ in CAN Bus Line - Short to B+ in CAN Bus Line DESCRIPTION There may be a short circuit between the CAN bus line and +B when there is resistance between terminals 6 (CANH) and 16 (BAT) or terminals 14 (CANL) and 16 (BAT) of the DLC3. HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU WIRING DIAGRAM Page 7372 (a) Using SST, compress the coil spring. SST : 09727-30021 09727-00010 09727-00021 09727-00031 NOTICE: * Do not compress the coil spring more than necessary. * Do not use an impact wrench. It will damage SST. (b) Install the coil spring to the shock absorber. HINT Fit the lower end of the coil spring into the recess of the spring seat of the shock absorber. 2. INSTALL FRONT SUSPENSION SUPPORT SUB-ASSEMBLY LH (a) Install the 2 cushions, 2 retainers and suspension support to the piston rod. (b) Temporarily install a new suspension support to front shock absorber nut. (c) Position the suspension support as shown in the illustration. (d) Remove SST. NOTICE: Do not use an impact wrench. It will damage the shock absorber rod. Page 5244 2. Inspect the front driveshaft (propeller shaft assembly) for a loose parts label that may be contacting other components (see Figure 1). Is the label on the front driveshaft (propeller shaft assembly) loose and contacting other components? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the cause of this condition. 3. Completely remove the front driveshaft parts label. 4. Test drive and confirm there is no abnormal noise present when in 4WD. Page 6296 J/B No.3 - Instrument Panel Right Page 2458 Intake Manifold: Service and Repair Removal 1UR-FE INTAKE: INTAKE MANIFOLD: REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal 2. REMOVE EGR VALVE ASSEMBLY (a) Remove the EGR valve See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Valve/Service and Repair/Removal. 3. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY (a) Remove the front wiper motor and link See: Wiper and Washer Systems/Wiper Motor/Service and Repair/Removal. 4. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY (a) Disconnect the washer hose and 2 wire harness clamps. (b) Remove the 7 bolts and outer panel. 5. REMOVE VENTILATION HOSE ASSEMBLY (a) Disconnect the ventilation hose from the ventilation pipe of the cylinder head cover LH and RH. (b) Remove the bolt and ventilation hose. 6. REMOVE AIR TUBE SUB-ASSEMBLY LH See: Cooling System/Thermostat/Service and Repair/Removal 7. REMOVE INTAKE MANIFOLD (a) Disconnect the No. 4 water by-pass hose. (b) Disconnect the throttle body connector. (c) Disconnect the No. 1 ventilation hose. (d) Disconnect the purge VSV connector. Page 7280 Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal. (b) for 3UR-FBE: Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal. (c) for 1UR-FE: Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal. (d) for 3UR-FE: Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal. 4. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (a) Put matchmarks on the No. 2 steering intermediate shaft and the power steering gear. (b) Remove the bolt and disconnect the No. 2 steering intermediate shaft from the power steering gear. 5. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (a) Remove the cotter pin and nut. (b) Using SST, disconnect the tie rod end LH from the steering knuckle. SST : 09610-20012 NOTICE: * Hang SST with a string, etc. to prevent it from falling. * Do not damage the front disc brake dust cover. * Do not damage the ball joint dust cover. * Do not damage the steering knuckle. 6. DISCONNECT TIE ROD END SUB-ASSEMBLY RH HINT Up to 11/2009 Brake Fluid Solenoid Valve Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 4478 Throttle Body: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 3. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 4. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 5. REMOVE THROTTLE BODY ASSEMBLY (a) Disconnect the 2 water by-pass hoses. (b) Disconnect the throttle position sensor and control motor connector. (c) Remove the 4 bolts, throttle body and gasket. (d) Remove the No. 12 water by-pass hose from the throttle body. (e) Remove the No. 4 water by-pass hose from the throttle body. Page 8067 * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. 3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: * For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the front airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for Double Cab) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. Page 5926 Yaw Rate Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 2472 Crankshaft Main Bearing Seal: Service and Repair Removal 1UR-FE ENGINE MECHANICAL: REAR CRANKSHAFT OIL SEAL: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (a) for 2WD: Refer to the following procedures . (b) for 4WD: Refer to the following procedures See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal. 3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 4. REMOVE REAR CRANKSHAFT OIL SEAL (a) Using a knife, cut off the lip of the oil seal. (b) Using a screwdriver, pry out the oil seal. NOTICE: Do not damage the surface of the oil seal press fit hole and crankshaft. HINT Tape the screwdriver tip before use. Service and Repair Keyless Entry Transmitter Battery: Service and Repair DOOR LOCK: TRANSMITTER BATTERY: REPLACEMENT 1. REPLACE TRANSMITTER BATTERY NOTICE: Be careful when handling each component as they are precision electronic components. (a) Insert a precision screwdriver into the gap, and turn the screwdriver to detach the cover. HINT Tape the screwdriver tip before use. NOTICE: Do not forcibly pry up the cover. (b) Remove the battery (lithium battery: CR2032). NOTICE: * Do not push the terminals with your finger. * Do not forcibly pry up the battery. The terminals may be damaged. * Do not touch the battery with wet hands. Water may cause rust. * Do not touch or move any components inside the transmitter, it may interfere with the proper operation. (c) Install a battery (lithium battery: CR2032) with the positive (+) side facing upward, as shown in the illustration. NOTICE: * Do not bend the transmitter battery electrode during insertion. * Keep the transmitter cover interior free of dust and oil. (d) Attach the cover securely. Page 2054 Page 1379 Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 9167 Auxiliary Step / Running Board: By Symptom Technical Service Bulletin # SB0164-10 Date: 100628 Body - Tube Step Step Pad Lifting/Cracking T-SB-0164-10 June 28, 2010 Tube Step - Step Pad Lifting/Cracked Service Category Vehicle Exterior Section Exterior Panels/Trim Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a condition where the step pad has lifted or cracked. To improve the serviceability of the tube step the step pad is now available as a separate service part. Follow the procedure in this bulletin to replace the step pad. Removal of the tube step is not required to perform step pad replacement. Parts Information Warranty Information APPLICABLE WARRANTY ^ Toyota accessories installed as original equipment are 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. ^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months, regardless of mileage, from the date of installation on the vehicle, or the remainder of the applicable New Vehicle Limited Warranty, whichever provides the greater coverage. ^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of purchase. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Repair Procedure Page 4836 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type ..................................................................................................................................................... ......................................... Toyota Genuine ATF WS Notice: Using automatic transmission fluid other than "Toyota Genuine ATF WS" may cause deterioration in shift quality, locking up of your transmission accompanied by vibration, and ultimately damage the automatic transmission of your vehicle. Page 9343 (2) w/ Front Fender Mudguard: Install the front fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and Repair/Installation. (3) w/ Side Step: Install the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and Replacement/Installation. (b) for Resin Type Bumper: Install the fender apron mudguard seal. (1) Install the fender apron mudguard with the 2 clips and 15 new clips labeled A. (2) Install the pin hold clip so that its groove is vertical. (3) w/ Front Fender Mudguard: Install the front fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and Repair/Installation. (4) w/ Side Step: Install the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and Replacement/Installation. Page 9179 Auxiliary Step / Running Board: Overhaul Disassembly EXTERIOR: SIDE STEP: DISASSEMBLY 1. REMOVE STEP PLATE COVER LH (a) for Double Cab: Remove the step plate cover. (1) Detach the 19 clips and remove the step plate cover. (b) for CrewMax: Remove the step plate cover. (1) Detach the 23 clips and remove the step plate cover. 2. REMOVE STEP COVER PROTECTOR LH 3. REMOVE STEP ARM SPACER LH 4. REMOVE SIDE STEP BRACKET LH (a) Remove the 2 bolts and side step bracket. Page 7655 Page 3956 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 5365 Four Wheel Drive Selector Switch: Diagrams Page 7719 Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 6. REMOVE LOWER INSTRUMENT PANEL (a) for Column Shift Type: Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 7. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) for Column Shift Type: Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 9. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (a) Remove the screw and duct. 10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY Page 9036 Trailer Towing Part 3 Page 4054 Canister Purge Control Valve: Service and Repair Installation 1UR-FE EMISSION CONTROL: PURGE VALVE: INSTALLATION 1. INSTALL PURGE VSV (a) Install the purge VSV with the bolt. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) (b) Connect the connector. 2. CONNECT PURGE LINE HOSE (a) Connect the 2 hoses. HINT Turn the claw of the clip to the upper side. 3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 5550 Four Wheel Drive Selector Switch: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION 1. INSTALL 4WD CONTROL SWITCH (a) Attach the 3 claws to install the switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 2158 Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: * No further tightening is required once the nut is tightened with the specified torque. * Check that there is no foreign matter on the washer and nut. * Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve, washer and nut. Failing to do so may result in improper installation. (d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main body of the tire pressure warning valve and transmitter in the shaded area as shown in the illustration. NOTICE: * If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will interfere with the tire pressure warning valve and transmitter, and may cause damage to it. * If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the tire pressure warning valve and transmitter. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is not clamped by the bead. (f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: Page 1728 Fuel Pressure: Testing and Inspection 1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. NOTICE: Do not start the engine. (c) Turn the Techstream main switch ON. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (e) Check the fuel pump operation. (1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard. If there is no sound, check the integration relay, fuel pump, ECM and wiring connector. (f) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. 2. CHECK FUEL PRESSURE (a) Check that the battery voltage is 11 to 14 V. (b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions. (c) Disconnect the cable from the negative (-) battery terminal. (d) Remove the fuel pipe clamp from the fuel tube connector. (e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it. CAUTION: * Always read the precautions See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions before disconnecting the fuel tube connector (quick type). * The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. Page 6356 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 4651 Actuator: Service and Repair Removal DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Disconnect the actuator hose. (b) Disconnect the actuator connector. (c) Remove the 4 bolts and actuator. Air Conditioning System (for Automatic Air Conditioning System) Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 7677 Compressor Clutch Relay: Testing and Inspection AIR CONDITIONING: MAGNETIC CLUTCH RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAGNETIC CLUTCH RELAY (MG CLT) (a) Remove the magnetic clutch relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: * If the result is not as specified, replace the relay. (c) Install the magnetic clutch relay. Page 4592 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 2071 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 1702 Standard toe-in (unloaded vehicle): for Double Cab of Long Deck Standard toe-in (unloaded vehicle): for CrewMax of standard deck Page 9276 Hood Shock / Support: Service and Repair Installation ENGINE HOOD / DOOR: HOOD SUPPORT: INSTALLATION NOTICE: * As much as possible avoid touching the stroke portions of the rod to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing. * Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks. * Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed. HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. INSTALL NO. 1 HOOD SUPPORT BOLT (a) Install the hood support bolt. Torque : 22 Nm (224 kgf-cm, 16 ft-lbf) CAUTION: Install the hood support bolt while supporting the hood by hand. 2. INSTALL HOOD SUPPORT ASSEMBLY LH (a) Install the hood support assembly. CAUTION: Install the hood support while supporting the hood by hand. NOTICE: Check that the hood support is engaged in the ball joint and it cannot be pulled out. Page 3242 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 2086 Engine Room R/B, J/B - Engine Compartment Left Page 5729 without union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf) with union nut wrench - Torque : 14 Nm (145 kgf-cm, 10 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). * This torque value is effective when union nut wrench is parallel to the torque wrench. NOTICE: * Do not bend or damage the brake tube. * Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting point. 2. BLEED BRAKE LINE See: Brake Bleeding/Service and Repair/Bleeding 3. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Installation Page 2727 (b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) HINT Install the monolithic converter protector within the angle range specified in the illustration. 5. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Install the sensor to the front No. 2 exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 6. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Air Fuel Ratio Sensor/Installation 7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (b) Connect the air fuel ratio sensor connector. 8. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Installation 9. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (a) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts. Page 366 M. Turn ignition OFF for a minimum of 10 seconds. Then click Next. N. Turn ignition to the ON position. Then click Next. 0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish. Locations Washer Fluid Level Switch: Locations WIPER AND WASHER: WIPER AND WASHER SYSTEM: PARTS LOCATION Page 6828 Page 8430 Antenna, Navigation: Service and Repair Installation NAVIGATION: NAVIGATION ANTENNA: INSTALLATION 1. INSTALL NAVIGATION ANTENNA ASSEMBLY (a) Install the antenna with the 2 screws. (b) Attach the clamp. 2. INSTALL DEFROSTER NOZZLE ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly 3. INSTALL NO. 1 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly 4. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly 5. INSTALL NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly 6. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components Oil Filter: Service and Repair Components 1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS Page 4908 Removal A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard Page 1065 (b) Disconnect the connector and remove the courtesy switch. Installation LIGHTING: REAR DOOR COURTESY SWITCH: INSTALLATION HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL REAR DOOR COURTESY SWITCH (a) Connect the connector. (b) Install the courtesy switch with the bolt. Page 2858 Fuel Pump Control Unit: Service and Repair Removal 1UR-FE FUEL: FUEL PUMP ECU: REMOVAL 1. REMOVE FUEL PUMP ECU (a) Disconnect the 2 fuel pump ECU connectors. (b) Remove the 2 bolts and fuel pump ECU. NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being dropped, etc. Up to 11/2009 Electronic Brake Control Module: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Control Module: Service and Repair Components JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS Page 2007 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 8214 (a) Check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Page 622 Remote Switch: Testing and Inspection AUDIO / VISUAL: STEERING PAD SWITCH: INSPECTION 1. INSPECT STEERING PAD SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the steering pad switch assembly. Occupant Classification System Air Bag Control Module: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 841 Wheel Speed Sensor: Service and Repair Rear Speed Sensor Components BRAKE CONTROL: REAR SPEED SENSOR: COMPONENTS Removal BRAKE CONTROL: REAR SPEED SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 8233 (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 3. REMOVE FRONT SEAT ASSEMBLY (for Power Seat) (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 4. REMOVE FRONT SEAT INNER CUSHION SHIELD (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly 5. REMOVE FRONT SEAT INNER BELT ASSEMBLY (a) Driver Side: Disconnect the 2 connectors and detach the 4 clamps. (b) Passenger Side: Disconnect the connector and detach the clamp. (c) Remove the nut and front seat inner belt. Installation SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: INSTALLATION 1. INSTALL FRONT SEAT INNER BELT ASSEMBLY (a) Install the front seat inner belt with the nut. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) NOTICE: Do not allow the anchor part of the front seat inner belt to overlap the protruding part of the front seat adjuster. (b) Driver Side: (1) Connect the 2 connectors and attach the 4 clamps. (c) Passenger Side: Page 4479 Throttle Body: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: INSTALLATION 1. INSTALL THROTTLE BODY ASSEMBLY (a) Install the No. 4 water by-pass hose to the throttle body. HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration. (b) Install the No. 12 water by-pass hose to the throttle body. HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration. (c) Install a new gasket to the intake air surge tank. HINT Align the protrusion of the gasket with the groove of the intake air surge tank. (d) Install the throttle body with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (e) Connect the throttle position sensor and control motor connector. Page 3089 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 1466 Symbols Used Within Diagrams Symbols Used Within Diagrams Air Conditioning System (for Automatic Air Conditioning System) Compressor Speed Sensor: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 477 Seat Occupant Classification Module - Air Bag: Testing and Inspection SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: ON-VEHICLE INSPECTION 1. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the ECU. CAUTION: * For removal and installation procedures of the occupant classification ECU, be sure to follow the correct procedure. * If the airbags have deployed, replace the occupant classification ECU on the side in which the collision occurred. Replace both if necessary. Page 1047 Dome Lamp Switch: Diagrams Page 6059 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 7650 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 2929 Engine Temperature Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Partially immerse the sensor in water and warm up the water. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the engine coolant temperature sensor. NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. HINT If the result is as specified, do not replace the engine coolant temperature sensor. Page 3769 Accelerator Pedal Position Sensor: Diagrams Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Page 6242 Fuse: Application and ID Fuse Layout and Amperage Ratings Fuse Block Location - Engine Compartment Fuse Location - Engine Compartment Page 9295 Components Control Module: Service and Repair Components JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS Page 9041 Connectors Part 4 Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. See: Locations Page 1916 Standard condition: Indicator light [D] remains illuminated for 2 seconds and then turns off. (f) When using the Techstream: Return the shift lever to P and terminate the Active Test on the Techstream. (g) When not using the Techstream: Return the shift lever to P and disconnect SST from the DLC3. (h) Allow the engine to idle until the fluid temperature reaches 53 to 59°C (127 to 138°F). HINT The indicator [D] will come on again when the fluid temperature reaches 53°C (127°F) and will blink if it is higher than 59°C (138°F). (i) Remove the overflow plug and gasket with the engine idling. (j) Wait until the overflow slows to a trickle. NOTICE: If the fluid does not overflow, perform the following: (1) Remove the refill plug and gasket. (2) Refill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. (3) Wait until the overflow slows to a trickle. (4) Install a new gasket and the refill plug. Torque : 39 Nm (400 kgf-cm, 29 ft-lbf) (k) Install a new gasket and the overflow plug. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) 6. COMPLETE (a) Turn the ignition switch off. Emissions - MIL ON/Multiple Air Injection DTC's Set Air Diverter Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 6447 Power Distribution Relay: Diagrams Page 4184 Page 4958 (a) Coat 2 new O-rings with ATF and install them to the grooves of the transmission oil cooler. (b) Install the transmission oil cooler to the transmission oil cooler spacer with the 3 bolts. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) (c) Install the 2 No. 1 transmission oil cooler hoses to the transmission oil cooler spacer. NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the illustration. (d) Connect the 2 No. 1 transmission oil cooler hoses to the transmission. NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the illustration. (e) Temporarily install the transmission oil cooler together with the transmission oil cooler spacer with bolt C. Temporarily install bolt A and bolt B. Tighten the bolts in alphabetical order. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 7. CONNECT WATER BY-PASS PIPE ASSEMBLY (a) Connect the 2 water by-pass hoses to the transmission oil cooler and connect the water by-pass pipe with the bolt. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: Make sure the paint marks and pinching portion of each clip are facing the directions shown in the illustration. 8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) for Regular Cab Standard Deck: Install the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. (b) except Regular Cab Standard Deck: Page 1626 Page 3224 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 6547 Relay Box: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 6872 Power Distribution Relay: Testing and Inspection ACC Relay 1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAIN BODY ECU (ACC RELAY) (a) Measure the resistance of the ACC relay circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the main body ECU. Page 7410 (h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for work that can be finished quickly. Safety stands must be used to support the vehicle. Page 6949 Driver Side J/B Inner Circuit Page 8246 (a) Align the vehicle's claws with the seat belt retractor positioning holes. (b) Install the seat belt with the 2 bolts. HINT First install bolt A, and then install bolt B. for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Connect the pretensioner connector as shown in the illustration. (d) Install the shoulder anchor to the shoulder belt anchor adjuster with the nut. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 3. INSTALL LOWER CENTER PILLAR GARNISH Page 6806 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 6162 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 2010 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 5301 (c) Align the matchmarks on the joint yoke and intermediate shaft. (d) Install the washer. (e) Clamp the yoke in a vise, and press the bearing into position by installing a new lock nut. Torque : 128 Nm (1305 kgf-cm, 94 ft-lbf) (f) Loosen the lock nut. (g) Tighten the lock nut again. Torque : 128 Nm (1305 kgf-cm, 94 ft-lbf) (h) Using a chisel and hammer, stake the lock nut. 3. INSTALL REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (for 3 Joint Type) (a) Apply MP grease to a new spider and 4 new bearings. NOTICE: Be careful not to apply too much grease. (b) Measure dimension A between the snap ring grooves. (c) Install the 4 spider bearings to the spider journal portions, and then measure dimension B of the universal joint. Page 2938 Page 763 Acceleration/Deceleration Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6318 JQ1-LJ1 Locations Collision Avoidance Module: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 8114 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY Page 7622 Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 5062 30. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER SHAFT (a) Check for wear and damage to the clutch hub and side gear inter shaft. (b) Check that the clutch sleeve slides smoothly on the side gear inter shaft. 31. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE (a) Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve. Maximum clearance: 0.35 mm (0.0138 in.) (b) If the clearance exceeds the maximum, replace the fork or clutch sleeve. Reassembly DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REASSEMBLY 1. INSTALL STRAIGHT PIN (a) Using a plastic-faced hammer, tap in the straight pins until their protrusion amounts are at the specified values shown in the illustration below. Page 6519 Relay Box: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 4914 (c) Insert a thin-bladed screwdriver, release the locking lug of terminal 4 (SFTD-), 5 (SFTD+) and 11 (E), and pull the terminals out from the rear. (d) Detach the 2 claws and remove the control shaft tube clamp from the column shift control shift lever retainer. 6. REMOVE SHIFT LOCK SOLENOID (a) Detach the 2 claws and remove the shift lock solenoid bracket. (b) Remove the screw, collar, 2 bushes and shift lock solenoid with No. 1 shift lock plate sub-assembly from the column shift control shift lever retainer. (c) Insert a thin-bladed screwdriver, release the locking lug of terminal 1 (SLS+) and 8 (E), and pull the terminals out from the rear. Page 2466 (a) Install the front wiper motor and link See: Wiper and Washer Systems/Wiper Motor/Service and Repair/Installation. 15. INSTALL EGR VALVE ASSEMBLY (a) Install the EGR valve See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Valve/Service and Repair/Installation. 16. CHECK FOR FUEL LEAK See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Installation Page 1024 Ambient Light Sensor: Service and Repair Installation LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: INSTALLATION 1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (a) Attach the 2 claws to install the sensor. (b) Connect the connector. 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. Page 162 Page 3554 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE 4WD CONTROL ECU BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (4WD CONTROL ECU - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Disconnect the A26 4WD control ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: (d) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE 4WD CONTROL ECU Page 579 Hood Sensor/Switch (For Alarm): Diagrams Page 4953 Transmission Cooler: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: OIL COOLER: REMOVAL 1. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 2. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) for Regular Cab Standard Deck: Remove the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. (b) except Regular Cab Standard Deck: Remove the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal. 3. DISCONNECT WATER BY-PASS PIPE ASSEMBLY (a) Remove the bolt and disconnect the 2 water by-pass hoses from the transmission oil cooler to disconnect the water by-pass pipe. HINT Use a container to catch any coolant which flows out of the water by-pass hoses. 4. REMOVE TRANSMISSION OIL COOLER ASSEMBLY (w/o Trailer Towing System) (a) Disconnect the 2 No. 1 transmission oil cooler hoses from the transmission. (b) Remove the 3 bolts and transmission oil cooler with transmission oil cooler spacer. (c) Remove the 2 No. 1 transmission oil cooler hoses from the transmission oil cooler spacer. (d) Remove the 3 bolts and transmission oil cooler from the transmission oil cooler spacer. (e) Remove the 2 O-rings from the grooves of the transmission oil cooler. 5. REMOVE TRANSMISSION OIL COOLER ASSEMBLY (w/ Trailer Towing System) Components Manifold Pressure/Vacuum Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: COMPONENTS Door Control Receiver (for CrewMax) Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax) Components DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS Removal DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal ACC Cut Relay Power Distribution Relay: Testing and Inspection ACC Cut Relay 1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION 1. REMOVE ACC CUT RELAY (a) Remove the clip. (b) Detach the 2 clips and remove the cowl side trim board RH. (c) Remove the relay. 2. INSPECT ACC CUT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL ACC CUT RELAY (a) Install the relay. (b) Attach the 2 clips to install the cowl side trim board RH. (c) Install the clip. Page 9365 8. With the cab still raised install the new No.3 cab mounts 9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to specification. Torque: 61 N*m (622 kgf*cm, 45 ft*lbf) 10. Lower the cab back onto the No.3 cab mount. 11. Install the new bolt through the No.3 cab mount and install the NEW larger washer and NEW nut and torque to specifications. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) Page 8469 Alarm System Transmitter: Service and Repair Removal ENGINE IMMOBILISER: TRANSPONDER KEY ECU: REMOVAL 1. REMOVE AIR CONDITIONING UNIT (a) Remove the air conditioning unit See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Removal. 2. REMOVE TRANSPONDER KEY BRACKET (w/ Bracket) (a) Remove the 2 screws and transponder key bracket. 3. REMOVE TRANSPONDER KEY ECU (a) Disconnect the lower part of the ECU, and then upper part in that order to remove the ECU. Page 8344 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 2830 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 1647 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 8813 Page 5266 4. INSPECT NO. 1 CENTER SUPPORT BEARING ASSEMBLY (for 3 Joint Type) (a) Check that the bearing turns freely. * If the bearing is damaged, worn, or does not turn freely, replace it. Page 4677 Control Module: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION 1. INSTALL 4WD CONTROL ECU (a) Install the ECU with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. Page 7032 *: for 5 leaf spring Standard Caster Inclination for Regular Cab of Standard Deck Components Alarm Module: Service and Repair Components THEFT DETERRENT: THEFT WARNING ECU: COMPONENTS Page 3877 Variable Valve Timing Actuator Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE VVT SENSOR (a) Disconnect the 4 sensor connectors. (b) Remove the 4 bolts and 4 sensors. Page 474 Page 9133 Trailer Connector: Electrical Diagrams Trailer Towing Part 1 Page 2062 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 3326 Page 6183 Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Floor Shift Type) Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL 1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal Page 7125 Power Steering Pressure Switch: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT POWER STEERING OIL PRESSURE SWITCH (a) Check the oil pressure switch. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch on. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering pressure. (5) Start the engine. (6) Operate the steering wheel while idling, and read the value on the Techstream. Standard: (7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Inspect the power steering system See: Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Components Power Distribution Module: Service and Repair Components OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS Page 8791 (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 3. INSPECT FRONT NO. 4 SPEAKER ASSEMBLY (for 10 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Instrument Panel Speaker (for Regular Cab) AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): INSPECTION 1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 4347 (4) Install the O-ring to the fuel injector. (5) Install SST and the tube to the fuel injector. SST : 09268-31012 09268-41500 90467-13001 95336-08070 09268-41300 09268-41600 (6) Put the injector into a graduated cylinder. CAUTION: Install a strong rubber tube onto the injector to prevent gasoline from splashing. (7) Operate the fuel pump (turn the ignition switch to ON). (8) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times. SST : 09842-30090 Standard injection volume: 83 to 99 cm3 (5.0 to 6.0 cu in.) per 15 seconds Difference between each injector: 16 cm3 (1.0 cu in.) or less (9) If the injection volume is not as specified, replace the injector assembly. Page 5145 5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal. SST : 09308-10010 6. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 7. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST, remove the front bearing (inner race). SST : 09556-22010 (b) Using SST, remove the bearing (outer race). SST : 09308-00010 8. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER 9. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer. 10. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST and a hammer, tap in the bearing (outer race). SST : 09316-60011 09316-00011 09316-00021 Page 7770 (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. 10. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 11. REMOVE BLOWER CASE SUB-ASSEMBLY (a) Remove the 3 screws. (b) Detach the 2 claws and remove the case. 12. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 13. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) Page 8954 Replacement/Rear Bumper (for Resin Type Bumper)/Installation 7. INSTALL REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 8. INSTALL REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 9. INSTALL REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 10. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 11. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 12. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 13. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Page 1381 Impact Sensor: Testing and Inspection Side Airbag Sensor (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 3090 Locations Manifold Pressure/Vacuum Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5907 Page 8027 Air Bag Deactivation Switch: Diagrams Curtain Airbag Cutoff Switch Components Tire Pressure Module: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS Page 6157 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 4871 Transmission Speed Sensor: Testing and Inspection A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION 1. INSPECT SPEED SENSOR NT (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. 2. INSPECT SPEED SENSOR SP2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. Page 8078 Page 3477 NOTICE: *1: MIL turns on only during VSC or ABS failure status. Reading and Clearing Diagnostic Trouble Codes MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: DTC CHECK / CLEAR HINT Refer to the Techstream operator's manual for further details. 1. CHECK DTC (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch ON. (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Main Body / Trouble Codes. (e) Read the DTCs. Page 6778 Page 5270 Page 2677 Engine Temperature Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the sensor. (b) Using a 19 mm ball joint lock nut wrench, install the sensor. Torque : 20 Nm (200 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench See: Service Precautions (c) Connect the sensor connector. 2. ADD ENGINE COOLANT See: Coolant/Service and Repair 3. INSPECT FOR COOLANT LEAK See: Testing and Inspection 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Bleeding Brake Bleeding: Service and Repair Bleeding BRAKE: BRAKE FLUID: BLEEDING NOTICE: * Perform fluid replacement with the parking brake applied. * Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir. * Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off immediately. * After adding brake fluid, make sure the reservoir is sufficiently full. * When bleeding air, select the suitable procedure listed below. 1. BLEED BRAKE LINE (a) Bleed brake line (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (7) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. (10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (13)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (b) Check and bleed brake system. (1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform the following air bleed procedures. Locations Tire Pressure Warning Reset Switch: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 5928 Yaw Rate Sensor: Testing and Inspection BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION 1. CHECK YAW RATE SENSOR (a) Check the yaw rate sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 4489 Variable Induction Control Solenoid: Diagrams Page 3353 Information Bus: Locations CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION Page 3055 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 6614 Auxiliary Power Outlet: Connector Views Power Outlet Socket Components Oil Pressure Sender: Service and Repair Components 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: COMPONENTS Page 2483 * Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. * Ensure that no oil is on the mounting surface of the cylinder head. HINT The cylinder head bolts are tightened in 3 progressive steps. (b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. (c) Step 1: Page 699 Page 8323 Air Bag Deactivation Switch: Service and Repair Curtain Shield Airbag Cutoff Switch Components SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Disconnect the connector. Page 6632 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 10. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL POWER OUTLET SOCKET COVER Locations Sunroof / Moonroof Module: Locations SLIDING ROOF: SLIDING ROOF SYSTEM: PARTS LOCATION Page 3232 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 5757 Parking Brake Cable: Service and Repair Removal PARKING BRAKE: PARKING BRAKE CABLE: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 5. RELEASE PARKING BRAKE PEDAL 6. DISCONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY See: Parking Brake Pedal/Service and Repair/Removal and Replacement/Removal 7. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1GR-FE) (a) for Regular Cab Standard Deck: Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. 8. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1GR-FE) (a) for Regular Cab Standard Deck: Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. (b) except Regular Cab Standard Deck: Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal. 9. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1UR-FE) (a) for Regular Cab Standard Deck: Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. 10. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FE) (a) for Regular Cab Standard Deck: Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. 11. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FBE) (a) for Regular Cab Standard Deck: Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. 12. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1UR-FE) Locations Entertainment System Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 2006 "Case2" 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 1387 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 2924 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 3106 Page 6831 Page 587 Integrated Accessory Switch Assembly: Service and Repair Removal METER: DRIVE MONITOR SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE DRIVE MONITOR SWITCH (a) Detach the 2 claws and remove the monitor switch. Page 186 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2480 (b) Install the 16 valve stem caps to the cylinder head. 6. INSTALL VALVE LASH ADJUSTER ASSEMBLY (a) Inspect the valve lash adjuster See: Testing and Inspection/Engine Unit. (b) Install the 16 lash adjusters to the cylinder head. NOTICE: Install the lash adjuster at the same place it was removed from. 7. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY (a) Apply engine oil to the lash adjuster tips and valve stem cap ends. (b) Install the 16 valve rocker arms as shown in the illustration. 8. INSTALL CAMSHAFTS (for Bank 1) (a) Install the camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Camshaft (for Bank 1)/Installation. 9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Install the exhaust manifold LH See: Exhaust System/Exhaust Manifold/Service and Repair/Installation. Page 8023 Locations Horn Relay: Locations HORN: HORN SYSTEM: PARTS LOCATION Page 8649 Entertainment System Control Module: Diagrams Page 3467 (b) Wait 1 minute and then check the display of the connected ECUs and sensors. NOTICE: ECUs and sensors that are not present will not be displayed. Be careful not to mistake them for communication stop malfunctions. HINT * If the display of an ECU is intermittent during the check, one side of an ECU or sensor branch wire is open. (The signal of the ECU is treated as noise, which affects the response and display of the Techstream.) * The main body ECU checks for proper ECU communication for ECUs that are connected to the CAN MS bus circuit, and the results are displayed on the Techstream. If communication stops between an ECU and the main body ECU for 10 seconds or more, the ECU disappears from the Techstream display. * For communication stop mode of ECUs connected to the CAN MS bus circuit, refer to the DTC flowchart of the respective communication stop. B -- GO TO DTC U1002 FLOWCHART See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1002 C -- GO TO MAIN BODY ECU COMMUNICATION STOP MODE FLOWCHART See: Component Tests and General Diagnostics/Main Body ECU Communication Stop Mode D -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN Communication System/Problem Symptoms Table E -- GO TO OPEN IN ONE SIDE OF CAN BRANCH WIRE FLOWCHART See: Symptom Related Diagnostic Procedures/CAN Communication System A -- Continue to next step. 9. CHECK COMMUNICATION MALFUNCTION DTC (PAST DTC CHECK)* (a) Select "CAN Bus Check" from the "System Select". (b) Write down all of the DTCs stored in each ECU. HINT * If there are communication malfunction DTCs stored but the Techstream's "CAN Bus Check Communication Bus Check" screen displays all of the ECUs and sensors connected to the CAN system, the communication malfunction DTCs may be past malfunctions that are no longer present. * For V bus main wire malfunctions, related ECUs are also detected. Therefore, determine the malfunctioning area based on all of the DTCs that are output. * For MS bus malfunctions, DTCs are output based on the detection of communication stop malfunctions and network malfunctions of ECUs that are connected by the main body ECU. B -- GO TO DTC U1002 FLOWCHART See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1002 Disassembly Parking Brake Warning Switch: Service and Repair Disassembly PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and switch. Page 4354 Fuel Injector: Service and Repair Installation 1UR-FE FUEL: FUEL INJECTOR: INSTALLATION 1. INSTALL FUEL INJECTOR ASSEMBLY (a) Attach the 3 clamps to install the No. 6 wire harness to the delivery pipe RH. (b) Attach the 3 clamps to install the No. 7 wire harness to the delivery pipe LH. (c) Apply gasoline or spindle oil to a new O-ring and install it to the injector. NOTICE: Make sure that there is no damage or foreign material in the groove of the injector when installing the O-ring. (d) Connect the injector connector. (e) Install the injector to the delivery pipe as shown in the illustration. Page 4875 Transmission Speed Sensor: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION 1. INSTALL SPEED SENSOR SP2 (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. 2. INSTALL SPEED SENSOR NT (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. Page 9031 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 2358 (Cylinder block journal diameter - crankshaft journal diameter - 5) X 1000 = A + B Standard Bearing Chart: No. 1 and No. 5 Journals: Other Journals: EXAMPLE: No. 1 and No. 5 journals Cylinder block "7" + Crankshaft "6" = Total number 13 (Use upper bearing "6" and lower bearing "7") Other journals Cylinder block "7" + Crankshaft "6" = Total number 13 (Use upper bearing "5" and lower bearing "6") Standard Bearing Chart: Standard Cylinder Block Crankshaft Journal Bore Diameter (A) Standard Crankshaft Journal Diameter (B): Page 2661 If the fins are blocked, wash them with water or a steam cleaner. NOTICE: * If the distance between the steam cleaner and core is too close, the fins may be damaged. * Keep the following injection distance. Standard injection distance: * If the fins are bent, straighten them with a screwdriver or pliers. * Never apply water directly onto the electric components. (b) Dry the fins with compressed air. Page 9299 Page 475 Seat Occupant Classification Module - Air Bag: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 3715 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 4304 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 6826 Instrumental Panel Wire Air Conditioning System (for Automatic Air Conditioning System) Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 3046 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Locations Four Wheel Drive Selector Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Locations Transmission Temperature Sensor/Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 5887 Steering Angle Sensor: Service and Repair Removal BRAKE CONTROL: STEERING ANGLE SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 7. REMOVE LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 9. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal 10. REMOVE STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal Page 6599 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 262 Page 8792 (b) If the result is not as specified, replace the speaker assembly. Rear Door Speaker (for CrewMax) AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): INSPECTION 1. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for Standard) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for 12 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 3. INSPECT REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers) Page 8703 Seat Memory Switch: Service and Repair Installation SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSTALLATION 1. INSTALL SEAT MEMORY SWITCH (a) Install the seat memory with the 2 screws. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL FRONT DOOR ARMREST COVER LH 4. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly Page 3206 Crankshaft Position Sensor: Diagrams Locations Headlamp Relay: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 6749 Driver Side J/B Inner Circuit Page 6171 Power Outlet Socket (115V) Page 1923 Fluid - Differential: Service and Repair DIFFERENTIAL: DIFFERENTIAL OIL: REPLACEMENT 1. DRAIN DIFFERENTIAL OIL (a) Stop the vehicle on a level place. (b) for Front Differential: (1) Using a 10 mm hexagon wrench, remove the filler plug and gasket. (2) Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil. (3) Using a 10 mm hexagon wrench, install a new gasket and the drain plug. Torque : 39 Nm (398 kgf-cm, 29 ft-lbf) (c) for Rear Differential: (1) Remove the filler plug and gasket. (2) Remove the drain plug and gasket, and drain the oil. (3) Install a new gasket and the drain plug. Torque : 49 Nm (500 kgf-cm, 36 ft-lbf) 2. ADD DIFFERENTIAL OIL (a) Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the differential filler plug hole. NOTICE: * Too much or too little oil will lead to differential problems. * After changing the oil, drive the vehicle and then check the oil level again. Oil type: Front differential capacity: Rear differential capacity: Page 7769 (a) Disconnect the 2 connectors. (b) Remove the 4 screws and damper servo. (c) Remove the servo motor. (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. (d) Remove the servo motor. Radio Antenna Antenna, Radio: Service and Repair Radio Antenna Components AUDIO / VISUAL: RADIO ANTENNA: COMPONENTS Page 8532 (a) Detach the 4 clips. (b) Disconnect the connector and remove the panel. 11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE (a) Detach the 2 claws and remove the sensor. Installation THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE (a) Attach the 2 claws to install the sensor. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY Page 5583 Brake Fluid Solenoid Valve Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 147 Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Check Mode Procedure. Locations Tire Pressure Monitor Receiver / Transponder: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Skid Control Sensor Wire Wheel Speed Sensor: Diagrams Skid Control Sensor Wire Page 6543 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 7352 (a) Temporarily install the spring seat and 2 U bolts with the 4 washers and 4 nuts. NOTICE: * Tighten the nuts in the order shown in the illustration. * Install the U bolts so that the lengths of the 4 ends under the spring seat are the same. 6. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Connect the parking brake cable to the vehicle with the 3 bolts. for Bolt A - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) for Bolt B - Torque : 14 Nm (138 kgf-cm, 10 ft-lbf) 7. STABILIZE SUSPENSION See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Installation 8. TIGHTEN REAR SPRING ASSEMBLY LH (a) Tighten the 3 nuts. Torque : 105 Nm (1071 kgf-cm, 77 ft-lbf) 9. TIGHTEN REAR SPRING U BOLT (a) Tighten the 4 nuts. Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf) 10. INSTALL REAR WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 11. INSTALL SPARE TIRE 12. REMOVE SAFETY STANDS Page 302 Junction Connector (CAN No.2) - Lower Finish Panel Page 1873 ^ 1AR-FE (Highlander Venza) ^ 2AR-FE (RAV4 Camry) Warranty Information Required Tools & Equipment Page 1499 Ignition Switch: Connector Views Page 2972 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. (c) for 2WD: Connect the air fuel ratio sensor connector. 2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Connect the front No. 2 exhaust pipe to the exhaust pipe support. (b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (c) Connect the air fuel ratio sensor connector. (d) Connect the heated oxygen sensor connector. 3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) Page 8665 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 937 (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 14. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Remove the 3 screws and plate. (b) Detach the 3 claws and remove the heater clamp. (c) Remove the heater radiator unit. 16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY Page 6460 Page 8640 (a) Attach the 4 clips to install the light. NOTICE: Do not damage the design surface of the television display when you install the light. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 1729 (f) Install SST (pressure gauge) as shown in the illustration. SST : 09268-31012 90467-13001 95336-08070 09268-41500 09268-41120 SST : 09268-45014 09268-41200 09268-41220 (g) Wipe off any gasoline. (h) Reconnect the cable to the negative (-) battery terminal. (i) Operate the fuel pump. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. NOTICE: Do not start the engine. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (j) Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (k) If the pressure is higher than the specification, replace the fuel pressure regulator. If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator assembly. (l) Start the engine. Page 8035 (b) Detach the 2 claws and remove the switch. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: INSTALLATION 1. INSTALL CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Attach the 2 claws to install the switch. (b) Connect the connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 394 (c) WAVEFORM 2: HINT The wavelength varies in accordance with the engine operating conditions. (d) WAVEFORM 3: HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the heated oxygen sensor. (e) WAVEFORM 4: Page 461 (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 6495 Driver Side J/B - Cowl Side Left Locations Transmission Speed Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1677 *: for 5 leaf spring Standard Toe-in for Regular Cab of Standard Deck Page 4112 * Never reuse the O-ring. * When placing a new O-ring on the injector, do not damage it. * Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and intake manifold as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type). (1) for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration. (2) for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector. Page 6619 Connectors Part 1 Connectors Part 2 Page 5954 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Air Conditioning System (for Automatic Air Conditioning System) Air Door Actuator / Motor: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 6046 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 3276 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 676 (b) Attach the 2 clips and 5 claws to install the armrest base panel. Page 3495 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU (CANH, CANL) OK -- REPLACE COMBINATION METER ASSEMBLY 14. CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU) (a) Disconnect the J2 main body ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH, CANL) OK -- REPLACE MAIN BODY ECU 15. CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A17 skid control ECU with actuator connector. Page 5292 (c) Using a brass bar and hammer, slightly tap in the 4 spider bearings. (d) Using needle-nose pliers, remove the 4 snap rings from the grooves. (e) Using a screwdriver, remove the 4 slingers of the spider bearing. (f) Clamp the propeller shaft in a vise between aluminum plates. (g) Using SST, press in spider bearing B until spider bearing A can be clamped in a vise. SST : 09950-60010 09951-00290 SST : 09950-40011 09951-04010 09952-04010 09953-04030 09954-04010 09957-04010 09958-04011 Back Power Window Switch Power Window Switch: Testing and Inspection Back Power Window Switch WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: INSPECTION 1. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Check the resistance. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the power window regulator switch assembly. (b) Check that the LED illuminates. (1) Apply battery voltage to the power window regulator switch and check that the LED illuminates. OK: (2) If the result is not as specified, replace the power window regulator switch assembly. 2. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Power Slide Type) (a) Check the resistance. (1) Measure the resistance according to the value(s) in the table below. Page 2855 Fuel Pump Control Unit: Diagrams Locations Impact Sensor: Locations SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Glass Breakage Sensor (for Floor Shift Type) Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Floor Shift Type) Components THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): COMPONENTS Removal THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH Power Steering Oil Pressure Sensor Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor Page 2571 Page 2139 Tire Pressure Module: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the ECU with the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the ECU connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 7. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration. 8. PERFORM INITIALIZATION (a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 9. CHECK TIRE PRESSURE AFTER REPAIRS Locations Fuse Block: Locations Engine Compartment Page 3688 ^ 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 7055 Standard camber inclination (unloaded vehicle): for CrewMax of standard deck Page 1043 Cargo Lamp Switch: Service and Repair Installation LIGHTING: CARGO LIGHT SWITCH: INSTALLATION 1. INSTALL CARGO LIGHT SWITCH (a) Attach the 2 claws to install the light switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Double cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 2242 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 6257 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 2846 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection Page 1475 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 7046 Standard toe-in (unloaded vehicle): for Double Cab of Long Deck Standard toe-in (unloaded vehicle): for CrewMax of standard deck Page 1033 Brake Light Switch: Service and Repair Installation LIGHTING: STOP LIGHT SWITCH: INSTALLATION 1. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER (a) Attach the 2 claws to install the adjuster. 2. INSTALL STOP LIGHT SWITCH ASSEMBLY (a) Insert the stop light switch so that it contacts the pedal cushion. NOTICE: insert the stop light switch with a force of less than 98 N*m (1000 kgf*cm 72.3 ft.*lbf). (b) Rotate the stop light switch clockwise 90° to install it to the adjuster. Standard: A: 1.5 to 2.5 mm (0.0591 to 0.0984 in.) NOTICE: * When the stop light switch is rotated clockwise, make sure the stop light switch moves outward less than 1 pitch (pitch: distance between 2 screw threads). * Rotate the stop light switch with a torque of 1.5 N*m (15 kgf*cm.13 in.*lbf). * Do not allow silicon grease to contact the stop light switch. (c) Connect the connector. Page 4883 Shift Interlock Control Module: Diagrams Page 8138 Page 6305 Driver Side J/B Inner Circuit Page 7657 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 718 Seat)/Installation. Remote Starting System - Cold Weather Starting Tips Keyless Starting System: Technical Service Bulletins Remote Starting System - Cold Weather Starting Tips T-SB-0100-09 Rev1 March 31, 2009 Remote Engine Starter (RES) Cold Temperature Operation Diagnostic Tips Service Category Engine/Hybrid System Section Starting Market USA Applicability March 9, 2010 Rev1: TSB REVISION NOTICE Applicability has been updated to include applicable 2010 - 2011 model year vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Some vehicles operated in extremely cold temperatures may exhibit a condition where the Remote Engine Starter (RES) does not function. Before RES diagnosis confirm with the customer the ambient temperature when the malfunction was experienced. The RES system was designed to operate at temperatures above -22 F (-30 C). Non-operation of the RES system below this threshold should be considered a normal condition. Warranty Information Diagnostic Procedure Page 6461 Page 384 Standard Voltage: NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) OK -- REPLACE ECM See: Service and Repair/Removal 5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the ignition switch connector. (c) Disconnect the cable from the battery positive (+) terminal. (d) Remove the AM2 fuse and integration relay. Page 7807 Compressor Clutch Relay: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 8399 Page 4556 Camshaft Position Sensor: Diagrams Page 9075 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 4336 * Never reuse the O-ring. * When placing a new O-ring on the injector, do not damage it. * Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and intake manifold as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type). (1) for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration. (2) for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector. Page 3344 Engine Temperature Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Partially immerse the sensor in water and warm up the water. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the engine coolant temperature sensor. NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. HINT If the result is as specified, do not replace the engine coolant temperature sensor. Page 9372 3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount. 4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse. Page 832 Wheel Speed Sensor: Diagrams Front Speed Sensor Page 7914 Air Bag: Diagrams Front Side Airbag Squib Circuit A760F Automatic Transmission System Control Module: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 1917 (b) When using the Techstream: Disconnect the Techstream from the DLC3. (c) w/ Trailer Towing System (with transmission oil thermostat): (1) Push in the shaft with a screwdriver and remove the pin. NOTICE: Make sure the shaft of the thermostat is protruding from the hole in the cap. (d) Inspect for automatic transmission fluid leaks. Page 6249 Page 8287 (a) Attach the 6 clips to install the quarter trim panel lower. (b) Install the seat belt anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Attach the 2 claws to install the cover. 4. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL REAR SEAT ASSEMBLY (a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. Page 3324 Page 3489 HINT * *1: w/ Power Steering ECU * *2: w/ 4WD * *3: w/ Bus Buffer ECU Short in CAN Bus Lines CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short in CAN Bus Lines - Short in CAN Bus Lines DESCRIPTION There may be a short circuit between the CAN bus lines when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ohms. HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU WIRING DIAGRAM Page 4583 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 8006 Air Bag Control Module: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 6342 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 6493 Driver Side J/B - Cowl Side Left Page 2801 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 4580 Page 8267 (a) Remove the 2 bolts and bracket. Installation SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): INSTALLATION 1. INSTALL SEAT BELT BRACKET (a) Install the bracket with the 2 bolts. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL CENTER REAR SEAT OUTER BELT ASSEMBLY (a) Align the vehicle's claws with the seat belt retractor positioning holes. (b) Install the retractor with the 2 bolts. HINT First install bolt A, and then install bolt B. for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Install the seat belt with the 2 bolts. Page 2225 ^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F. ^ Using the Tire Pressure Chart (Figure 1), find the intersection of the warm tire line at the point corresponding to 54°F and read off the value on the tire pressure change axis. In this case it would be about 6.7 psi. ^ The tires should be filled to: 31.9 + 6.7 psi = 38.6 psi Example 3: Temperature Compensation - "Hot" Tires ^ The vehicle has been driven to the shop on the highway for at least 60 minutes (vehicle has "hot" tires) and tire pressures are set to 31.9 psi. ^ Workshop temperature is 68°F, and the expected lowest ambient temperature in the area is expected to be 14°F. ^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F. ^ Using the tire pressure chart (Figure 1), find the intersection of the hot tire line at the point corresponding to 54°F, and read off the value on the tire pressure change axis. In this case it would be about 9.0 psi. ^ The tires should be filled to: 31.9 + 9.0 psi = 40.9 psi Page 2089 Driver Side J/B - Cowl Side Left Page 6967 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Locations Turn Signal Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 5780 Parking Brake Pedal: Overhaul Disassembly PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and switch. Reassembly PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY 1. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the switch with the screw. Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf) Page 2188 Tire Pressure Module: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL NOTICE: * It is necessary to perform initialization See: Testing and Inspection/Programming and Relearning/Initialization after registration See: Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. * When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU using the intelligent tester or Techstream and write them down before removal. 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the ECU connector. (b) Remove the 2 nuts and ECU. Page 625 Remote Switch: Service and Repair Removal AUDIO / VISUAL: STEERING PAD SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD SWITCH ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws. (c) Detach the 4 pins and remove the steering pad switch. Page 8745 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 6626 (a) Attach the claw to install the power outlet socket. (b) Connect the power outlet socket connector. 6. INSTALL CENTER FRONT SEAT ASSEMBLY (a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation. 7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. 10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Page 6986 Page 6732 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Locations Power Distribution Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 6944 Junction Connector (CAN No.2) - Lower Finish Panel Page 2451 Intake Manifold: Description and Operation 1UR-FE INTAKE: INTAKE SYSTEM: SYSTEM DIAGRAM Page 6120 (c) Remove the starter pinion drive lever. (d) Remove the starter center bearing clutch from the starter yoke. 3. REMOVE STARTER BRUSH HOLDER ASSEMBLY (a) Remove the 2 screws and end frame. NOTICE: While holding down the lead wire, remove the starter commutator end frame. (b) Disconnect the 4 brushes from the starter brush holder. (1) Using a screwdriver, hold back the brush holder. (2) Disconnect the brush from the brush holder. (c) Remove the brush holder. 4. REMOVE STARTER YOKE ASSEMBLY (a) Remove the starter yoke from the starter armature. 5. REMOVE STARTER ARMATURE PLATE (a) Remove the starter armature plate from the starter center bearing clutch. Page 9391 shake is a normal and unavoidable condition in certain situations with this type of vehicle. Please use the chart below to show customers the comparison to competitors. Also, show the vehicle driver that reducing speed by as little as 5 mph has a considerable positive effect in reducing body vibration. 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 occurrence of the specified condition described in this bulletin. Parts Information Repair Procedure 1. Test drive the vehicle and confirm the condition. Repeat remaining steps for both No.3 cab mounts. 2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is necessary to allow the cab to be raised to remove the No.3 mount. Page 8077 Impact Sensor: Service and Repair Side Airbag Sensor (for CrewMax) Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): COMPONENTS Page 8920 Page 8269 Removal SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for CrewMax): REMOVAL 1. REMOVE REAR SEAT ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Crewmax RH Side)/Removal 2. REMOVE REAR NO. 1 SEAT INNER BELT ASSEMBLY RH Air Conditioning System (for Automatic Air Conditioning System) Compressor Clutch Relay: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 2336 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 9064 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 1478 "Case2" 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 1229 Throttle Position Sensor: Diagrams Page 3621 with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 5. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (b) Connect the air fuel ratio sensor connector. (c) Connect the heated oxygen sensor connector and 2 clamps. 6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation 8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Page 3415 Information Bus: Reading and Clearing Diagnostic Trouble Codes MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: DTC CHECK / CLEAR HINT Refer to the Techstream operator's manual for further details. 1. CHECK DTC (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch ON. (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Main Body / Trouble Codes. (e) Read the DTCs. 2. CLEAR DTC (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch ON. (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Main Body / Trouble Codes. (e) Clear the DTCs. Page 8658 Page 962 Solar Sensor: Service and Repair Removal AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): REMOVAL 1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Detach the 2 claws. (b) Disconnect the connector and remove the sensor. Page 91 (h) If the result is not as specified, the seat heater control may have a malfunction. Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 8010 Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Recall 09V388000: Floor Mat/Accelerator Interference Accelerator Pedal: Recalls Recall 09V388000: Floor Mat/Accelerator Interference VEHICLE MAKE/MODEL: MODEL YEAR(S): Lexus/ES350 2007-2010 Lexus/IS 2006-2010 Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Prius 2004-2009 Toyota/Tacoma 2005-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor Corporation MFR'S REPORT DATE: October 05, 2009 NHTSA CAMPAIGN ID NUMBER: 09V388000 NHTSA Action Number: N/A COMPONENT: Vehicle Speed Control: Accelerator Pedal POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: Toyota is recalling certain model year 2004-2010 passenger vehicles. The accelerator pedal can get stuck in the wide open position due to its being trapped by an unsecured or incompatible driver's floor mat. CONSEQUENCE: A stuck open accelerator pedal may result in very high vehicle speeds and make it difficult to stop the vehicle, which could cause a crash, serious injury or death. REMEDY: Toyota will notify owners of affected vehicles to remove any driver's floor mat and not replace it with any other floor mat pending the development of model-specific remedies. Toyota will mail a second notification to owners of affected vehicles notifying them of the free remedies when they are available. The first notice is expected to be mailed during October 2009 and Toyota will advise NHTSA of the estimated date when the remedies will be available. Owners may contact Toyota at 1-800-331-4331, Lexus at 1-800-255-3987. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 4015 Air Injection Control Valve: Service and Repair Air Switching Valve (for Bank 2) Components 1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): COMPONENTS Removal Components Power Mirror Switch: Service and Repair Components MIRROR: OUTER MIRROR SWITCH: COMPONENTS Page 7047 (b) * for 5 leaf spring * If the toe-in is not as specified, adjust it at the rack ends. 4. ADJUST TOE-IN (a) Release the rack boot set 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 to the center value. (d) Check that the length of the right and left rack ends are approximately the same. Page 3976 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 3359 Locations Relay Box: Locations Engine Compartment Page 2309 HINT The crankshaft timing gear and camshaft exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears. (d) Install the crankshaft timing sprocket to the crankshaft. (e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear. (f) Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear. NOTICE: Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed. (g) Remove the pin from the No. 2 chain tensioner. 5. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH HINT If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner. 6. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. (c) Install a new gasket and the chain tensioner with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 7. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH (a) Install the vibration damper with the 2 bolts. Page 6685 Driver Side J/B - Cowl Side Left Page 8752 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 6328 Multiple Junction Connector: Locations Wire and Wire In Seat [Bench Seat] JT1 JT1 Page 194 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Locations Temperature Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 8380 Page 6923 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 2767 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. Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power Source Circuit DESCRIPTION When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil, closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and +B2 of the ECM. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN) Page 7351 2. INSTALL TUBE (a) Install the tube to the bush. 3. TEMPORARILY INSTALL REAR SPRING ASSEMBLY LH (a) Temporarily install the spring with the No. 2 spring shackle plate, shackle outer plate, 2 washers and 2 nuts to the rear side. (b) Temporarily install the spring with the bolt, washer and nut to the front side. 4. INSTALL REAR SPRING BUMPER SUB-ASSEMBLY (a) Install the spring bumper. NOTICE: Align the leaf spring center bolt and nut with the installation hole of the rear axle housing and spring bumper so that they are not loose. 5. TEMPORARILY INSTALL REAR SPRING U BOLT Drivetrain - Front Driveshaft Ticking Noise In 4WD Drive/Propeller Shaft: Customer Interest Drivetrain - Front Driveshaft Ticking Noise In 4WD T-SB-0045-10 January 27, 2010 Front Propeller Shaft Parts Label Delaminating - Ticking Noise Service Category Drivetrain Section Drive Shaft/Propeller Shaft Market USA Applicability Introduction Some 2008 - 2010 model year 4WD Sequoia and 2007 - 2010 model year 4WD Tundra vehicles may have a ticking noise present only when in 4WD. Production changes have been made to correct this condition. Follow the procedure in this bulletin to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Repair Procedure 1. Confirm there is a ticking noise only present in 4WD. Page 2384 Assenmacher Specialty Tools 1-800-525-2943 Page 7939 (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the roof headlining (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (e) Remove the roof headlining (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (f) Install SST. (1) Disconnect the connector from the curtain shield airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) After connecting SST each other, connect them to the curtain shield airbag. SST : 09082-00700 SST : 09082-00802 09082-10801 09082-40800 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Move SST at least 10 m (32.8 ft.) away from the vehicle rear side window. (4) Maintaining enough clearance for SST wire harness in the rear side window, close all doors and windows of the vehicle. Page 2462 Intake Manifold: Service and Repair Installation 1UR-FE INTAKE: INTAKE MANIFOLD: INSTALLATION 1. INSTALL THROTTLE BODY ASSEMBLY (a) Align the protrusion of a new gasket with the groove of the intake manifold, and install the gasket. (b) Install the throttle body with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR See: Powertrain Management/Computers and Control Systems/Manifold Pressure/Vacuum Sensor/Service and Repair/Installation 3. INSTALL UNION TO CONNECTOR TUBE HOSE ASSEMBLY (a) Install the union to connector tube hose to the intake manifold. (b) Install the 2 bolts and attach the hose clamp. Torque : 8.2 Nm (84 kgf-cm, 73 in-lbf) (c) Install the 2 wire harness brackets with the 2 bolts. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) 4. INSTALL PURGE VSV (a) Connect the purge line hose to the intake manifold. (b) Install the purge VSV to the intake manifold with the bolt. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 5. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) (a) Install the vacuum switching valve to the intake manifold with the bolt. Page 8199 (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 2. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET (a) Remove the 3 bolts and 3 anchor brackets. Installation SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Double Cab): INSTALLATION 1. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET (a) Align the holes with the positioning pins and install the 3 anchor brackets with the 3 bolts. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL REAR SEAT ASSEMBLY (a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. Page 2284 Page 9268 (a) Using a screwdriver, detach the cable from the clamps shown in the illustration. HINT Tape the screwdriver tip before use. (b) Pull the cable from the engine room and remove it. Page 3705 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 1316 Push the terminal retainer down to the temporary lock position. Page 4427 Fuel Pump Control Unit: Service and Repair Installation 1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION 1. INSTALL FUEL PUMP ECU (a) Install the fuel pump ECU with the 2 bolts. Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being dropped, etc. (b) Connect the 2 fuel pump ECU connectors. Page 3111 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Page 2802 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 1565 Tire Pressure Warning Reset Switch: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING RESET SWITCH (a) Attach the 2 claws to install the reset switch. (b) Connect the switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 1177 Page 8301 Page 3183 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Transmission Control Switch Transmission Mode Switch: Diagrams Transmission Control Switch Page 674 Power Door Lock Switch: Service and Repair Door Control Switch (for Front RH) Components DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): COMPONENTS Removal DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): REMOVAL 1. REMOVE FRONT ARMREST UPPER BASE PANEL RH Up to 11/2009 Yaw Rate Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6141 Page 3736 HINT The wavelength becomes shorter as the engine rpm increases. (n) WAVEFORM 13: HINT The waveform varies depending on the CAN communication signal. (o) WAVEFORM 14: HINT The waveform varies depending on the CAN communication signal. (p) WAVEFORM 15: HINT The wavelength becomes shorter as the engine rpm increases. Differential Carrier Oil Seal Seals and Gaskets: Service and Repair Differential Carrier Oil Seal Components DIFFERENTIAL: DIFFERENTIAL CARRIER OIL SEAL (for 1GR-FE, 1UR-FE): COMPONENTS Replacement DIFFERENTIAL: DIFFERENTIAL CARRIER OIL SEAL (for 1GR-FE, 1UR-FE): REPLACEMENT 1. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair Page 8279 3. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP (a) Partially remove the front door opening trim weatherstrip so that the lower quarter trim panel and front quarter trim panel can be removed. 6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY (a) Detach the 2 claws and remove the cover. (b) Remove the bolt and seat belt anchor. (c) for LH Side: Detach the 4 clips and remove the lower quarter trim panel. Components Integrated Accessory Switch Assembly: Service and Repair Components METER: DRIVE MONITOR SWITCH: COMPONENTS Page 6302 Engine Room R/B And Engine Room J/B Inner Circuit Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 7767 Housing Assembly HVAC: Overhaul Disassembly AIR CONDITIONING: AIR CONDITIONING UNIT: DISASSEMBLY 1. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY (a) Detach the 4 claws and remove the nozzle. 2. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (a) Detach the 4 claws and remove the duct. 3. REMOVE AIR FILTER COVER PLATE (a) Detach the 2 clips and remove the plate. 4. REMOVE CLEAN AIR FILTER Page 5882 Steering Angle Sensor: Programming and Relearning BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION PERFORM INITIALIZATION OF STEERING ANGLE SENSOR NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will become misaligned. (a) Check that the steering wheel is in the centered position. (b) Disconnect the negative battery terminal for more than 2 seconds. NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. (c) Reconnect the negative battery terminal. Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 1655 (b) Attach the 2 clips and 5 claws to install the rear upper door armrest base panel. Components Tire Pressure Monitor Receiver / Transponder: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS Page 5188 Air Conditioning System (for Automatic Air Conditioning System) Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 7288 (h) Using a screwdriver, remove the 4 control valve rings. NOTICE: Be careful not to damage the grooves for the control valve rings. 11. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Using SST and a press, remove the control valve upper bearing and control valve upper oil seal from the control valve housing. SST : 09950-60010 09951-00250 SST : 09950-70010 09951-07150 12. REMOVE CYLINDER END STOPPER (a) Using a screwdriver and hammer, turn the cylinder end stopper clockwise until the wire end can be seen through the service hole. (b) Using a screwdriver and hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper. 13. REMOVE POWER STEERING RACK 14. REMOVE POWER STEERING RACK BUSH (a) Remove the rack bush from the power steering rack. (b) Using a screwdriver, remove the O-ring from the rack bush. (c) Using SST, remove the rack bush oil seal. SST : 09527-21011 SST : 09612-24014 Page 6381 Components Canister Purge Control Valve: Service and Repair Components 1UR-FE EMISSION CONTROL: PURGE VALVE: COMPONENTS Page 1718 Standard steering axis inclination (unloaded vehicle): for Double Cab of Long Deck Page 3230 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. A/C Amplifier, A/C Blower Assembly Control Module HVAC: Diagrams A/C Amplifier, A/C Blower Assembly Page 2461 14. REMOVE UNION TO CONNECTOR TUBE HOSE ASSEMBLY (a) Remove the 2 bolts and detach the hose clamp. (b) Remove the union to connector tube hose from the intake manifold. (c) Remove the 2 bolts and 2 wire harness brackets. 15. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR See: Powertrain Management/Computers and Control Systems/Manifold Pressure/Vacuum Sensor/Service and Repair/Removal 16. REMOVE THROTTLE BODY ASSEMBLY (a) Remove the 4 bolts, throttle body and gasket. Page 3247 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Components Hazard Warning Switch: Service and Repair Components LIGHTING: HAZARD WARNING SWITCH: COMPONENTS Page 1426 Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 4. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 6. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 8. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 9. REMOVE FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 10. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Page 6595 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4276 ^ 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 5064 (b) Using snap ring pliers, install a new snap ring. 4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST and a plastic-faced hammer, tap in a new oil seal. SST : 09608-32010 Standard oil seal depth: 4.8 to 5.8 mm (0.189 to 0.228 in.) (b) Coat the lip of the oil seal with MP grease. 5. INSTALL DIFFERENTIAL CLUTCH HUB (a) Install the clutch hub onto the side gear inter shaft. (b) Using snap ring pliers, install a new snap ring. NOTICE: Be sure to install the differential clutch hub in the correct direction. 6. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING (a) Using SST and a press, press in 2 new bearings. Page 8073 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components Engine Oil: Service and Repair Components 1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS Page 5043 HINT First fit a washer with the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary. (b) Using SST and a press, press in the rear bearing (inner race). SST : 09506-35010 10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Install the drive pinion, front bearing (inner race) and oil slinger. HINT Assemble the spacer and oil seal after adjusting the gear contact pattern. (b) Using SST, install the companion flange. SST : 09950-30012 09951-03010 09953-03010 09954-03010 09956-03050 SST : 09955-03050 (c) Using SST to hold the companion flange. Page 6491 Engine Room R/B, J/B - Engine Compartment Left Components Ignition Switch: Service and Repair Components 1UR-FE STARTING: IGNITION SWITCH: COMPONENTS Specifications Fuel Pressure: Specifications FUEL PRESSURE Page 8982 (a) Connect the connector. (b) Attach the 4 clips to install the panel. 3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Locations Data Link Connector: Locations CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION Page 3329 HINT The wavelength becomes shorter as the engine rpm increases. (f) WAVEFORM 5: HINT * The wavelength becomes shorter as the engine rpm increases. * The waveforms and amplitudes displayed differ slightly depending on the vehicle. (g) WAVEFORM 6: HINT The wavelength becomes shorter as engine rpm increases. (h) WAVEFORM 7: Page 6200 (a) Disconnect the connector. (b) Using a screwdriver, detach the 5 claws and remove the console box bezel. HINT Tape the screwdriver tip before use. 3. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 4. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. Page 5544 Four Wheel Drive Selector Switch: Testing and Inspection JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION 1. INSPECT 4WD CONTROL SWITCH (a) Check the harness and connector (ECU - battery and body ground). (1) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage: (2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning, repair or replace harness or connector. If the harness or connector is normal, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. Standard resistance: (3) If there is a malfunction, repair or replace the harness or connector. (b) Check the harness and connector (switch - ECU). (1) Disconnect the A25 ECU connector. (2) Disconnect the L1 switch connector. (3) Measure the resistance according to the value(s) in the table below. Page 7978 Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) NOTICE: Do not twist the curtain shield airbag when installing it. (b) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 2. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY (for Double Cab) (a) Install the curtain shield airbag with the 8 bolts. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) NOTICE: Do not twist the curtain shield airbag when installing it. (b) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 3. INSTALL ROOF HEADLINING ASSEMBLY (a) Refer to the procedures from "INSTALL ROOF HEADLINING ASSEMBLY" (for Double cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (b) Refer to the procedures from "INSTALL ROOF HEADLINING ASSEMBLY" (for regular cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. CHECK SRS WARNING LIGHT Page 2070 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 1209 Removal 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL CAUTION: * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal 3. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Disconnect the heated oxygen sensor connector and 2 clamps. (b) Disconnect the air fuel ratio sensor connector. (c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH. 4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Using SST, remove the sensor. SST : 09224-00010 Page 6849 Rear Door Wire Rear Sonar Wire Page 9229 (f) Attach the clip. 2. INSTALL FRONT DOOR ARMREST COVER LH 3. INSTALL COURTESY LIGHT ASSEMBLY (w/ Power Window) (a) Attach the claw to install the courtesy light. (b) Connect the connector. 4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (a) Attach the 3 clips to install the front lower door frame bracket garnish. 5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window) (a) Install the plate and regulator handle with the snap ring. HINT With the door window fully closed, install the plate and the regulator handle with the snap ring as shown in the illustration. 6. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Power Window) (a) Install the power window regulator master switch with the 3 screws. 7. INSTALL FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window) Page 3563 (b) Measure the resistance according to the value(s) in the table below. 8. CHECK AIR CONDITIONING AMPLIFIER (a) Disconnect the J19 ECU connector. (b) Measure the resistance according to the value(s) in the table below. 9. CHECK CENTER AIRBAG SENSOR (a) Disconnect the J46 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Page 9240 HINT Tape the screwdriver tip before use. 2. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH (a) Using a screwdriver, detach the 2 clips and rear upper door armrest base panel. Then disconnect the connector. HINT Tape the screwdriver tip before use. 3. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Detach the 4 claws and remove the power window regulator switch. 4. REMOVE REAR DOOR FRAME GARNISH LH (a) Detach the 5 clips and remove the rear door frame garnish. 5. REMOVE COURTESY LIGHT ASSEMBLY (a) Detach the claw and remove the courtesy light from the door trim board. Page 1531 Power Steering Pressure Switch: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install a new O-ring to the power steering oil pressure switch. (b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch. NOTICE: * When reusing the power steering oil pressure switch, inspect the O-ring. * If the O-ring has scratches or cuts, replace the power steering oil pressure switch. (c) Using SST, install the power steering oil pressure switch. SST : 09922-10010 without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the torque wrench are connected in a straight line. (d) Connect the oil pressure switch connector. 2. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 3. ADD POWER STEERING FLUID 4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 5. INSPECT FOR POWER STEERING FLUID LEAK 6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Locations Parking Assist Distance Sensor: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 2315 (a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. (b) Install the No. 1 and No. 2 camshafts to the camshaft housing. (c) Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions. (d) Temporarily install the 10 bolts in the order shown in the illustration. 2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH (a) Make sure that the valve rocker arms are installed as shown in the illustration. (b) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.5 to 4.0 mm (0.138 to 0.157 in.) Page 3225 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 2957 Applicable Vehicles Page 1388 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 6852 Page 7666 (b) Remove the 2 bolts and 2 nuts. (c) Remove the 2 stud bolts and cooler compressor. Installation AIR CONDITIONING: COMPRESSOR (for 1UR-FE): INSTALLATION 1. ADJUST COMPRESSOR OIL (a) When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside the new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) NOTICE: * When checking the compressor oil level, follow the A/C system's precautions. * If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure. * If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage. * Be sure to use ND-OIL 8 or equivalent for compressor oil. 2. INSTALL COOLER COMPRESSOR ASSEMBLY (a) Install the cooler compressor and 2 stud bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Install the 2 bolts and 2 nuts. Torque : 24.5 Nm (250 kgf-cm, 18 ft-lbf) HINT Tighten the bolts and nuts in the order shown in the illustration to install the cooler compressor. (c) Connect the connector. 3. CONNECT SUCTION HOSE (a) Remove the attached vinyl tape from the cooler refrigerant suction hose. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: Page 2207 Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: * No further tightening is required once the nut is tightened with the specified torque. * Check that there is no foreign matter on the washer and nut. * Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve, washer and nut. Failing to do so may result in improper installation. (d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main body of the tire pressure warning valve and transmitter in the shaded area as shown in the illustration. NOTICE: * If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will interfere with the tire pressure warning valve and transmitter, and may cause damage to it. * If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the tire pressure warning valve and transmitter. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is not clamped by the bead. (f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: Page 8836 (a) Using a screwdriver, detach the 4 clips and claw. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 5. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Using a screwdriver, detach the 4 clips and claw. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY LH (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. Page 855 Yaw Rate Sensor: Service and Repair Removal BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal 3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE YAW RATE SENSOR (a) Remove the 2 nuts (labeled A) and sensor. (b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the sensor bracket. Page 9178 Page 1081 Headlamp Alignment Switch: Diagrams Page 4146 Page 7171 (c) Using SST, disconnect the upper ball joint from the steering knuckle. SST : 09628-62011 (d) Remove the steering knuckle. 7. REMOVE KNUCKLE GREASE RETAINER CAP LH (for 2WD) (a) Using a screwdriver and hammer, tap out the retainer cap. 8. REMOVE STEERING KNUCKLE OIL SEAL LH (for 4WD) (a) Using a screwdriver and hammer, tap out the oil seal. Testing and Inspection Parking Assist Switch: Testing and Inspection PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSPECTION 1. INSPECT DRIVE MONITOR SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the monitor switch. (c) Inspect the switch illumination. (1) Connect the positive (+) lead of the battery to terminal 1 (ILL+) and the negative (-) lead to terminal 6 (ILL-). (2) Check that the LED comes on. OK: LED comes on. (3) If the result is not as specified, replace the monitor switch. Page 6248 Page 7740 4. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) (a) Install the damper servo with the 3 screws, as shown in the illustration. (b) Connect the connector. 5. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. 6. INSTALL BLOWER CASE SUB-ASSEMBLY (a) Attach the 3 claws to install the case. (b) Install the 3 screws. Page 6108 (i) If the undercut depth is less than the minimum, correct it with a hacksaw blade. 3. INSPECT BRUSH (a) Using a vernier caliper, measure the brush length. Standard length: 15.0 mm (0.591 in.) Minimum length: 9.0 mm (0.354 in.) (b) If the brush length is less than the minimum, replace the starter yoke assembly and starter brush holder assembly. 4. INSPECT STARTER BRUSH HOLDER ASSEMBLY (a) Inspect the insulation. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the starter brush holder assembly. Components Steering Control Module: Service and Repair Components POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS Page 2425 (a) Hook the engine under cover to the vehicle body as shown in the illustration. (b) Install the 3 screws and 5 bolts. for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf) Diagrams Liftgate Window Motor: Diagrams Page 4507 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 8338 Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Front Airbag Sensor SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE INSPECTION 1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 6404 Recall - Accelerator Pedal Modification Technical Service Bulletin # SC-A0A Date: 110219 Page 5914 2. INSTALL FRONT SPEED SENSOR LH (a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E). Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) NOTICE: * Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part. * While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip part. * After installing the speed sensor, make sure there is no clearance or foreign matter between the sensor stay part and the knuckle. * Make sure there is no foreign matter attached to the magnetic rotor. 3. INSTALL FRONT SKID CONTROL SENSOR WIRE LH (a) Connect the connector (labeled A). (b) Install the 3 harness clamps (labeled B) with the 3 bolts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamps, do not twist the wire harness. * For clamps with rotation stoppers, make sure the rotation stopper touches the installation position. (c) Install the harness clamp with the bolt (labeled D). Page 2565 Variable Valve Timing Actuator: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. 6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) (a) Disconnect the oil control valve connector. (b) Remove the bolt and oil control valve. (c) Remove the O-ring from the oil control valve. Page 7087 Steering Control Module: Service and Repair Removal POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE POWER STEERING ECU ASSEMBLY (a) Disconnect the power steering ECU connector. (b) Remove the nut and power steering ECU. Page 1664 Wiper Switch: Diagrams Specifications Engine Oil Pressure: Specifications ENGINE OIL PRESSURE Page 5864 Braking Sensor/Switch: Diagrams Page 5325 Control Module: Diagrams Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5738 HINT * *1: FR RH * *2: FR LH * *3: RR RH * *4: RR LH * *5: FR Master Cylinder * *6: RR Master Cylinder (b) Using a union nut wrench, disconnect the 2 brake tubes from the VSC actuator. (c) Using a union nut wrench, remove the 2 brake tubes from the brake master cylinder. 4. DISCONNECT BRAKE TUBE (a) Using a union nut wrench, disconnect the 4 brake tubes from the VSC actuator. (b) Remove the clamp from the VSC actuator bracket. 5. REMOVE VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY (a) Remove the 3 nuts and VSC actuator with actuator bracket. Installation Page 7044 (b) : for 5 leaf spring Measuring points: A Ground clearance of the front drive shaft center B Ground clearance of the front adjusting cam bolt center C Ground clearance of the rear axle shaft center D Ground clearance of the leaf spring front side bushing center (c) If the vehicle height is not as specified, adjust the height by pressing down on the vehicle several times to stabilize the suspension. 3. INSPECT TOE-IN Airbag System Seat Occupant Sensor: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 306 Driver Side J/B Inner Circuit Page 1798 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 5442 Four Wheel Drive Selector Switch: Testing and Inspection JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION 1. INSPECT 4WD CONTROL SWITCH (a) Check the harness and connector (ECU - battery and body ground). (1) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage: (2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning, repair or replace harness or connector. If the harness or connector is normal, replace the 4WD control ECU See: Control Module/Service and Repair/Removal. Standard resistance: (3) If there is a malfunction, repair or replace the harness or connector. (b) Check the harness and connector (switch - ECU). (1) Disconnect the A25 ECU connector. (2) Disconnect the L1 switch connector. (3) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 3502 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (DLC3 BRANCH WIRE) (a) Disconnect the J86 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step. 3. CONNECT CONNECTOR Page 4537 Knock Sensor: Diagrams Page 7743 (a) Install the motor with the 3 screws. 11. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the amplifier with the 2 screws. 12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (a) install the duct with the screw. 13. INSTALL CLEAN AIR FILTER (a) Install the filter as shown in the illustration. 14. INSTALL AIR FILTER COVER PLATE (a) Attach the 2 clips to install the plate. Page 5004 Wiring Harness: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug and gasket, and drain the ATF. (b) Install a new gasket and the drain plug. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) 2. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY (a) Remove the 20 bolts, oil pan and gasket from the transmission. NOTICE: Some fluid will remain in the oil pan. Remove all the pan bolts, and carefully remove the oil pan assembly. (b) Examine the particles in the pan. (1) Remove the 4 magnets and use them to collect steel particles. Carefully inspect the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bush wear 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Remove the 4 bolts and oil strainer. NOTICE: Be careful as some fluid may leak out of the oil strainer. (b) Remove the O-ring from the oil strainer. 4. DISCONNECT TRANSMISSION WIRE Page 6717 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Adjustments Parking Assist Control Module: Adjustments PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: ADJUSTMENT 1. ADJUST BUZZER VOLUME (a) Turn the knob on the clearance warning ECU to adjust the volume. Page 4901 Page 3391 Information Bus: Connector Views Page 2016 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 9049 Page 6514 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 1511 Neutral Safety Switch: Component Tests and General Diagnostics A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the switch assembly. Page 4221 Accelerator Pedal: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: REMOVAL 1. REMOVE ACCELERATOR PEDAL ROD ASSEMBLY (a) Disconnect the accelerator pedal position sensor connector. (b) Remove the 2 nuts and accelerator pedal rod. Page 5980 Ignition Switch: Service and Repair Installation 1UR-FE STARTING: IGNITION SWITCH: INSTALLATION 1. INSTALL IGNITION SWITCH ASSEMBLY (a) Attach the 2 claws to install the ignition switch to the steering lock. 2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Reassembly 3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly 4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly 5. INSTALL STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation. (b) for Manual Tilt and Manual Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation. (c) for Power Tilt and Power Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 7977 Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal * Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY (for Regular Cab) (a) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 6 bolts and curtain shield airbag. 4. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY (for Double Cab) (a) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 8 bolts and curtain shield airbag. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: INSTALLATION 1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY (for Regular Cab) (a) Install the curtain shield airbag with the 6 bolts. Page 7963 (b) Remove the curtain shield airbag See: Removal and Replacement/Curtain Shield Airbag Assembly (for CrewMax)/Removal. (c) Cut off the deployment section of the curtain shield airbag. (d) Using a service-purpose wire harness for the vehicle, tie down the curtain shield airbag to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.00193 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2). HINT To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Position the curtain shield airbag inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Page 7367 Removal SUSPENSION: REAR SHOCK ABSORBER: REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 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 Page 1281 Camshaft Position Sensor: Diagrams Page 1417 Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): COMPONENTS Recall 09V388000: Floor Mat/Accelerator Interference Accelerator Pedal: All Technical Service Bulletins Recall 09V388000: Floor Mat/Accelerator Interference VEHICLE MAKE/MODEL: MODEL YEAR(S): Lexus/ES350 2007-2010 Lexus/IS 2006-2010 Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Prius 2004-2009 Toyota/Tacoma 2005-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor Corporation MFR'S REPORT DATE: October 05, 2009 NHTSA CAMPAIGN ID NUMBER: 09V388000 NHTSA Action Number: N/A COMPONENT: Vehicle Speed Control: Accelerator Pedal POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: Toyota is recalling certain model year 2004-2010 passenger vehicles. The accelerator pedal can get stuck in the wide open position due to its being trapped by an unsecured or incompatible driver's floor mat. CONSEQUENCE: A stuck open accelerator pedal may result in very high vehicle speeds and make it difficult to stop the vehicle, which could cause a crash, serious injury or death. REMEDY: Toyota will notify owners of affected vehicles to remove any driver's floor mat and not replace it with any other floor mat pending the development of model-specific remedies. Toyota will mail a second notification to owners of affected vehicles notifying them of the free remedies when they are available. The first notice is expected to be mailed during October 2009 and Toyota will advise NHTSA of the estimated date when the remedies will be available. Owners may contact Toyota at 1-800-331-4331, Lexus at 1-800-255-3987. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 3018 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 4794 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 7034 for Double Cab of Long Deck Page 3432 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU) OK -- Continue to next step. 12. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR) (a) Disconnect the J83 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR) OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR 13. CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU) (a) Disconnect the J28 combination meter ECU connector. Page 3447 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH, CANL) OK -- REPLACE MAIN BODY ECU 15. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A17 skid control ECU with actuator connector. Page 8981 (a) Detach the 4 clips. (b) Disconnect the connector and remove the panel. 11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE (a) Detach the 2 claws and remove the sensor. Installation THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE (a) Attach the 2 claws to install the sensor. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY Page 3083 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 4994 Valve Body: Overhaul Disassembly A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: DISASSEMBLY 1. REMOVE SHIFT SOLENOID VALVE SL2 (a) Remove the bolt, lock plate and 2 straight pins. (b) Remove the shift solenoid valve. 2. REMOVE SHIFT SOLENOID VALVE SLU 3. REMOVE SHIFT SOLENOID VALVE SLT (a) Remove the bolt, lock plate and 2 straight pins. (b) Remove the shift solenoid valve. 4. REMOVE SHIFT SOLENOID VALVE SL1 5. REMOVE SHIFT SOLENOID VALVE SR (a) Remove the bolt and shift solenoid valve. Page 3738 Engine Control Module: Programming and Relearning 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The Techstream is required to register the VIN. 1. DESCRIPTION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT This registration section consists of two parts: Read VIN and Write VIN. (a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read in order to confirm that the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the same. (b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM by following this procedure. 2. READ VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read. 3. WRITE VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write. Page 4527 Ignition Coil: Service and Repair Installation 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION 1. INSTALL SPARK PLUG (a) Using a 16 mm plug wrench, install the 8 spark plugs. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 2. INSTALL IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors. (3) Connect the 3 wire harness clamps. (b) for Bank 2: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors and 2 wire harness clamps. (3) Connect the water by-pass pipe with the 2 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) Remote Starting System - Cold Weather Starting Tips Keyless Starting System: Technical Service Bulletins Remote Starting System - Cold Weather Starting Tips T-SB-0100-09 Rev1 March 31, 2009 Remote Engine Starter (RES) Cold Temperature Operation Diagnostic Tips Service Category Engine/Hybrid System Section Starting Market USA Applicability March 9, 2010 Rev1: TSB REVISION NOTICE Applicability has been updated to include applicable 2010 - 2011 model year vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Some vehicles operated in extremely cold temperatures may exhibit a condition where the Remote Engine Starter (RES) does not function. Before RES diagnosis confirm with the customer the ambient temperature when the malfunction was experienced. The RES system was designed to operate at temperatures above -22 F (-30 C). Non-operation of the RES system below this threshold should be considered a normal condition. Warranty Information Diagnostic Procedure On-Vehicle Inspection Throttle Body: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: ON-VEHICLE INSPECTION 1. CHECK THROTTLE BODY ASSEMBLY (a) Check the throttle control motor operating sounds. (1) Turn the ignition switch to ON. (2) When depressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor. If friction noise exists, replace the throttle body. (b) Check the throttle position sensor. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Throttle Sensor Position. (5) Depress the accelerator pedal. When the throttle valve is fully opened, check that the value of "Throttle Sensor Position" is within the specification. Standard throttle valve opening percentage: 60% or more HINT When checking the standard throttle valve opening percentage, the shift lever should be in the N position. (6) If the percentage is less than 60%, replace the throttle body assembly. Page 4167 Page 3752 Oxygen Sensor Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (A/F) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the A/F fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the A/F fuse. (b) Measure the resistance of the A/F sensor heater relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 7449 Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: * No further tightening is required once the nut is tightened with the specified torque. * Check that there is no foreign matter on the washer and nut. * Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve, washer and nut. Failing to do so may result in improper installation. (d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main body of the tire pressure warning valve and transmitter in the shaded area as shown in the illustration. NOTICE: * If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will interfere with the tire pressure warning valve and transmitter, and may cause damage to it. * If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the tire pressure warning valve and transmitter. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is not clamped by the bead. (f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: Page 9105 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. Page 1258 Accelerator Pedal Position Sensor: Diagrams Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 6960 Page 6813 Page 2083 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 4106 Fuel Pressure: Testing and Inspection 1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. NOTICE: Do not start the engine. (c) Turn the Techstream main switch ON. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (e) Check the fuel pump operation. (1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard. If there is no sound, check the integration relay, fuel pump, ECM and wiring connector. (f) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. 2. CHECK FUEL PRESSURE (a) Check that the battery voltage is 11 to 14 V. (b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Service Precautions. (c) Disconnect the cable from the negative (-) battery terminal. (d) Remove the fuel pipe clamp from the fuel tube connector. (e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it. CAUTION: * Always read the precautions See: Service Precautions before disconnecting the fuel tube connector (quick type). * The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. (f) Install SST (pressure gauge) as shown in the illustration. Up to 11/2009 Wheel Speed Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 4769 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 4316 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 981 Door Switch: Diagrams Rear Door Courtesy Switch Page 400 Engine Control Module: Programming and Relearning 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The Techstream is required to register the VIN. 1. DESCRIPTION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT This registration section consists of two parts: Read VIN and Write VIN. (a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read in order to confirm that the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the same. (b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM by following this procedure. 2. READ VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read. 3. WRITE VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write. Page 3019 Accelerator Pedal Position Sensor: Diagrams Page 3558 (a) Measure the voltage and resistance according to the value(s) in the table below. HINT Check from the rear of the connector while it is connected to the air conditioning amplifier. * If the result is not as specified, the ECU may have a malfunction. 7. CHECK INTEGRATION CONTROL AND PANEL ASSEMBLY (a) Disconnect the J37 integration control and panel assembly connector. (b) Measure the voltage and resistance according to the value(s) in the table below. * If the result is not as specified, there may be a malfunction on the wire harness side. CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTICE: Before measuring the resistance, leave the vehicle for at least 1 minute and do not operate the ignition switch, any switches or doors. If Page 4161 Page 6571 Auxiliary Power Outlet Switch: Service and Repair Installation OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION 1. INSTALL INVERTER MAIN SWITCH (a) Attach the 2 claws to install the main switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 2549 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 7592 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 7627 Symbols Used Within Diagrams Symbols Used Within Diagrams Diagrams Variable Valve Timing Actuator Position Sensor: Diagrams Page 1411 (a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the battery in place. (b) Connect the cable to the positive (+) battery terminal. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): COMPONENTS Drivetrain - Front Driveshaft Ticking Noise In 4WD Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Front Driveshaft Ticking Noise In 4WD T-SB-0045-10 January 27, 2010 Front Propeller Shaft Parts Label Delaminating - Ticking Noise Service Category Drivetrain Section Drive Shaft/Propeller Shaft Market USA Applicability Introduction Some 2008 - 2010 model year 4WD Sequoia and 2007 - 2010 model year 4WD Tundra vehicles may have a ticking noise present only when in 4WD. Production changes have been made to correct this condition. Follow the procedure in this bulletin to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Repair Procedure 1. Confirm there is a ticking noise only present in 4WD. Page 8007 Air Bag Control Module: Diagrams Page 8826 A/T - Torque Converter Bolt Installation Precautions Flex Plate: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 2088 Driver Side J/B - Cowl Side Left Page 3862 Power Steering Pressure Switch: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install a new O-ring to the power steering oil pressure switch. (b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch. NOTICE: * When reusing the power steering oil pressure switch, inspect the O-ring. * If the O-ring has scratches or cuts, replace the power steering oil pressure switch. (c) Using SST, install the power steering oil pressure switch. SST : 09922-10010 without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the torque wrench are connected in a straight line. (d) Connect the oil pressure switch connector. 2. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 3. ADD POWER STEERING FLUID 4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 5. INSPECT FOR POWER STEERING FLUID LEAK 6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Side Airbag Sensor Impact Sensor: Diagrams Side Airbag Sensor Page 3245 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Components Ambient Temperature Sensor / Switch HVAC: Service and Repair Components AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: COMPONENTS Page 6848 Page 1603 Standard resistance: (4) If the resistance is not as specified, repair or replace the harness or connector. (c) Check the 4WD control switch. (1) Turn the ignition switch OFF. (2) Connect the L1 switch connector. (3) Connect the A25 and A26 ECU connectors. (4) Measure the voltage according to the value(s) in the table below. Standard voltage: (5) If the voltage is not as specified, check the 4WD control ECU. (d) Check the 4WD control ECU. (1) Disconnect the L1 switch connector. (2) Measure the voltage according to the value(s) in the table below. Page 4916 9. REMOVE TRANSMISSION CONTROL SWITCH (P POSITION) (a) Remove the 2 screws and switch from the column shift control shift lever retainer. Reassembly A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): REASSEMBLY 1. INSTALL TRANSMISSION CONTROL SWITCH (P POSITION) (a) Install the switch to the column shift control shift lever retainer with the 2 screws. 2. INSTALL TRANSMISSION CONTROL SWITCH (S POSITION) (a) Apply MP grease to the switch as shown in the illustration. (b) Install the switch to the column shift control shift lever retainer with the 2 screws. Page 2371 (4) for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector. (5) for Fuel Hose Connector Cover Type: Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration. (6) Check that there is no fuel leakage. 3. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See: Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection. Locations Relay Box: Locations Engine Compartment Page 8200 Child Restraint: Service and Repair Child Restraint Seat Anchor Bracket (for Regular Cab) Components SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Regular Cab): COMPONENTS Removal SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Regular Cab): REMOVAL HINT Move the seat to the foremost position before performing this procedure. Page 6384 Page 6115 Starter Motor: Overhaul Disassembly 1UR-FE STARTING: STARTER (for 1.6 kW Type): DISASSEMBLY 1. REMOVE MAGNET STARTER SWITCH ASSEMBLY (a) Remove the nut and disconnect the lead wire from the magnet starter switch. (b) Remove the 2 nuts from the starter drive housing while holding the magnet starter switch. (c) Pull the magnet starter switch and while lifting the front part of the magnet starter switch, release the plunger hook from the drive lever and remove the magnet starter switch. 2. REMOVE STARTER YOKE ASSEMBLY (a) Using a T25 "TORX" socket wrench, remove the 2 bolts. (b) Pull out the starter yoke together with the starter commutator end frame. (c) Remove the 2 screws and commutator end frame from the starter yoke. (d) Pull the starter yoke out of the starter commutator end frame. Page 4584 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 8900 Double Cab)/Removal 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 6. REMOVE REAR DOOR SCUFF PLATE RH (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT The procedures listed below are for the LH side. 7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH 3. INSTALL REAR DOOR SCUFF PLATE RH (a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT The procedures listed below are for the LH side. 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Page 6025 Torque : 4.6 Nm (47 kgf-cm, 41 in-lbf) 6. INSTALL GENERATOR PULLEY SST : 09820-63011 09820-06010 09820-06021 HINT (a) Clamp the generator housing stay in a vise. (b) Install SST 1-A to the pulley shaft. (c) Install SST 1-B to SST 1-A. (d) Install the pulley onto the rotor shaft by tightening the pulley nut by hand. (e) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque. Torque : 39 Nm (398 kgf-cm, 29 ft-lbf) NOTICE: Check that SST is secured to the rotor shaft. (f) Insert SST 2, and attach the pulley nut to SST 2. (g) Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration. Page 6797 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 5051 Standard preload (at starting): * If the preload is greater than the maximum, replace the bearing spacer. * If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached. Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less) * If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. HINT Do not loosen the pinion nut to reduce the preload. 25. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Standard total preload (at starting): Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf) 26. INSPECT DIFFERENTIAL RING GEAR BACKLASH (a) Using a dial indicator, check the backlash of the ring gear. Standard backlash: 0.10 to 0.20 mm (0.00394 to 0.00788 in.) * If the backlash is not as specified, adjust the side bearing preload or repair as necessary. Page 8264 14. INSTALL REAR SEAT CUSHION COVER WITH PAD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 15. CONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY (a) Connect the seat belt anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) HINT The rear No. 1 seat inner belt is fixed with the same bolt as the rear center seat outer belt's anchor. Therefore, connect it when installing the rear No. 1 seat inner belt. 16. INSTALL REAR SEAT ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Crewmax LH Side)/Installation 17. CONNECT REAR SEAT INNER BELT ASSEMBLY See: Rear Seat Inner Belt Assembly (for CrewMax)/Installation Components SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): COMPONENTS Page 9011 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. CAN Communication System Body Control Module: Locations CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION Page 8124 Page 9245 Rear Door Panel: Service and Repair Rear Door (for Double Cab) Up to 11/2009 ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): COMPONENTS Page 2005 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 5052 HINT Perform the measurements at 3 or more positions around the circumference of the ring gear. 27. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using a dial indicator, measure the runout of the companion flange vertically and laterally. Maximum runout: * If the runout is greater than the maximum, replace the companion flange. 28. STAKE REAR DRIVE PINION NUT (a) Using a chisel and hammer, stake the nut. 29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK (a) Install 2 new adjusting locks onto the bearing caps with the 2 bolts. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (b) Bend the nut locks. Disassembly DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): DISASSEMBLY 1. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Remove the 4 bolts. Components Transmission Speed Sensor: Service and Repair Components A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS Engine - Snow Ingestion Into Air Cleaner Box Front Fender Liner: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 935 10. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the 4 screws and damper servo. (c) Remove the damper servo. (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. (d) Remove the damper servo. Page 3414 NOTICE: *1: MIL turns on only during VSC or ABS failure status. Page 7702 Control Assembly: Service and Repair Air Conditioning Panel (for Floor Shift Type) Components AIR CONDITIONING: AIR CONDITIONING PANEL (for Floor Shift Type): COMPONENTS Page 626 Remote Switch: Service and Repair Installation AUDIO / VISUAL: STEERING PAD SWITCH: INSTALLATION 1. INSTALL STEERING PAD SWITCH ASSEMBLY (a) Attach the 4 pins to install the switch with the 2 screws. (b) Connect the connector. 2. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 3. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 4. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. INSPECT STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 7. CHECK SRS WARNING LIGHT See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation Page 6475 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 1408 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS Page 1054 Door Switch: Diagrams Rear Door Courtesy Switch Page 8331 Impact Sensor: Diagrams Door Side Airbag Sensor Page 8778 Tweeter Page 86 Power Seat Control Module: Diagrams Page 6919 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 6600 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Engine Controls - ECM Update For Shift Performance Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 6371 Page 9244 Up to 11/2009 Yaw Rate Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 5340 Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch Diagrams Television / Monitor: Diagrams Components Rear Vision Camera: Service and Repair Components PARK ASSIST / MONITORING: TELEVISION CAMERA: COMPONENTS Locations Steering Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 4808 Actuator: Diagrams Page 3965 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 6836 Junction Connector Page 4548 Ignition Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY (a) Remove the engine room relay block cover. (b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room relay block. HINT Tape the screwdriver tip before use. (c) Disconnect the 3 connectors. 2. INSPECT INTEGRATION RELAY (IG2) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the IG2 MAIN fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the IG2 MAIN fuse. (b) Measure the resistance of the ignition relay No. 2 (IG2). Page 7898 Solar Sensor: Service and Repair Removal AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): REMOVAL 1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Detach the 2 claws. (b) Disconnect the connector and remove the sensor. Components Cargo Lamp Switch: Service and Repair Components LIGHTING: CARGO LIGHT SWITCH: COMPONENTS Page 6780 Page 2648 3. INSTALL INLET RADIATOR HOSE (a) Install the inlet radiator hose. HINT The direction of each hose clamp is indicated in the illustration. 4. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Installation 5. ADD ENGINE COOLANT See: Coolant/Service and Repair 6. INSPECT FOR COOLANT LEAK See: Testing and Inspection 7. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 8. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 5029 Removal DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REMOVAL 1. REMOVE FRONT WHEELS 2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 3. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair 4. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (a) Remove the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Page 5647 Wheel Speed Sensor: Diagrams Rear Speed Sensor Components Actuator: Service and Repair Components DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): COMPONENTS Page 356 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 8493 Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS Page 1200 Oxygen Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 7196 (c) Align the notch of the front side plate with the notch of the front housing, and install the front side plate. NOTICE: Make sure that the front side plate is installed facing in the correct direction. 4. INSTALL VANE PUMP CAM RING (a) Coat the cam ring with the power steering fluid. (b) Align the notch of the cam ring with the notch of the front side plate, and install the cam ring with the inscribed mark facing upward. NOTICE: Make sure that the cam ring is installed facing in the correct direction. 5. INSTALL VANE PUMP ROTOR (a) Install the vane pump rotor. 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 4935 / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 13. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 14. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 15. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 6833 Page 4742 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 3521 Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR) OK -- Continue to next step. 10. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR STEERING ANGLE SENSOR) (a) Disconnect the J87 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (STEERING ANGLE SENSOR) OK -Continue to next step. 11. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR POWER STEERING ECU) NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)". (a) Disconnect the J115 No. 1 junction connector connector. Page 2837 (b) Install the connector holder block cover. 4. INSTALL AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and Repair/Installation 5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 3690 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 1098 Headlamp Dimmer Switch: Service and Repair Installation LIGHTING: HEADLIGHT DIMMER SWITCH: INSTALLATION 1. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Insert the headlight dimmer switch assembly onto the steering column while making sure that the switch's protrusions align with the shaft's cutout parts. (b) While loosening the band clamp, attach the claw to install the headlight dimmer switch assembly. (c) Connect the connector. 2. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (a) Attach the claw to install the windshield wiper switch. (b) Connect the connectors. 3. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 4. INSTALL TILT AND TELESCOPIC MANUAL SWITCH (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 5. INSTALL UPPER STEERING COLUMN COVER (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 6. INSTALL UPPER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation 7. INSTALL UPPER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Page 3152 (4) Connect the engine wire harness clamp. 3. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts. Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Tighten the hose clamp. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) (c) Connect the ventilation hose and vacuum hose. (d) Connect the MAF meter connector and clamp. 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 5825 Electronic Brake Control Module: Diagrams Page 8263 First install the bolt A, and then install the nut B. for bolt A - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) for nut B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (b) Install the belt sensor with the 3 nuts. for nut C - Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf) 2. INSTALL REAR SEAT SHOULDER BELT HOLE COVER (a) Install the seat belt as shown in the illustration. (b) Install the cover with the screw. 3. INSTALL REAR SEATBACK HINGE COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 4. INSTALL CENTER RECLINING ADJUSTER INSIDE COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 5. INSTALL REAR SEATBACK COVER WITH PAD See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 6. INSTALL LOWER REAR SEATBACK COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 7. INSTALL REAR SEAT LOCK CONTROL LEVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 8. INSTALL REAR SEATBACK LOCK STRIKER COVER LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 9. INSTALL REAR SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 10. INSTALL CENTER REAR SEAT HEADREST ASSEMBLY 11. INSTALL REAR SEAT HEADREST ASSEMBLY LH 12. INSTALL REAR SEAT ARMREST ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly 13. INSTALL REAR SEATBACK BOARD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Reassembly Diagram Information and Instructions Relay Box: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 3093 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 6653 (a) for AC Power Supply: Connect the clamp. (b) Install the bezel with the 4 screws. 5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly Components OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): COMPONENTS Page 2431 Repair Procedure Page 8130 Seat Occupant Classification Module - Air Bag: Service and Repair Removal SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY RH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE OCCUPANT CLASSIFICATION ECU (a) Disconnect the connector. (b) Detach the claw and remove the ECU from the seat. Page 810 Steering Angle Sensor: Service and Repair Removal BRAKE CONTROL: STEERING ANGLE SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 7. REMOVE LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 9. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal 10. REMOVE STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal Page 7589 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 4986 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. 5. INSPECT SHIFT SOLENOID VALVE S4 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: Page 5543 Four Wheel Drive Selector Switch: Diagrams Page 1090 Headlamp Dimmer Switch: Diagrams Page 844 Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Connect the speed sensor connector (labeled C). NOTICE: Securely connect the connector. 4. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Installation 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 6271 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4782 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 7041 Alignment: Service and Repair SUSPENSION: FRONT WHEEL ALIGNMENT: ADJUSTMENT NOTICE: For vehicles equipped with VSC, if wheel alignment has been adjusted, and if suspension or underbody components have been removed/installed or replaced, be sure to perform the following initialization procedure in order for the system to function normally: * Check that the steering wheel is in the centered position. * Disconnect the negative battery terminal for more than 2 seconds. * Reconnect the negative battery terminal. * Perform zero point calibration of the yaw rate and deceleration sensor and test mode inspection See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning 1. INSPECT TIRE (a) Inspect the tires See: Wheels and Tires/Testing and Inspection/Component Tests and General Diagnostics. 2. MEASURE VEHICLE HEIGHT NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specification. (a) Press down on the vehicle several times to stabilize the suspension, and then measure the vehicle height. Standard vehicle height (unloaded vehicle): for Regular Cab of Standard Deck Page 6767 AJ9-JI2 Page 8527 (a) Detach the 4 clips. (b) Disconnect the connector and remove the panel. 11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE (a) Detach the 2 claws and remove the sensor. Installation THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE (a) Attach the 2 claws to install the sensor. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY Page 1323 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 7447 Tire Pressure Sensor: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL 1. REMOVE TIRE 2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Remove the valve core and cap, and release the air from the tire. (b) After ensuring that a sufficient amount of air has been released, remove the nut and washer that is used to secure the tire pressure warning valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire. HINT Keep the removed cap, valve core, nut and washer. (c) Disengage the bead using the shoe of a tire remover. NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due to interference between the sensor and tire bead. (d) Remove the bead on the upper side. (e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on the lower side. HINT * The grommet is a non-reusable part. * Check that there are no cracks or damage on the grommet. If any damage is found, replace the washer and nut. Page 8820 * The procedures listed below are for the LH side. 1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) (a) Attach the 3 claws to install the speaker to the bracket. NOTICE: Do not touch the cone part of the speaker. (b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws. 2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 4 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR ARMREST COVER LH 5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Page 5961 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 2100 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 7667 ND-OIL 8 or equivalent (c) Install the O-ring on the cooler refrigerant suction hose. (d) Connect the cooler refrigerant suction hose on the cooler compressor with the bolt. Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) 4. CONNECT DISCHARGE HOSE (a) Remove the attached vinyl tape from the cooler refrigerant discharge hose. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the cooler refrigerant discharge hose. (d) Connect the cooler refrigerant discharge hose on the cooler compressor with the bolt. Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) 5. INSTALL FAN AND GENERATOR V BELT See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 6. INSTALL FENDER APRON MUDGUARD SEAL LH (a) Install the seal with the 6 clips. 7. CHARGE REFRIGERANT See: Service and Repair 8. WARM UP ENGINE See: Service and Repair 9. CHECK FOR REFRIGERANT GAS LEAK See: Service and Repair Page 6037 Removal and Replacement Power Steering Pump: Removal and Replacement Components POWER STEERING: VANE PUMP (for 1UR-FE): COMPONENTS Removal Page 378 Engine Control Module: Locations Engine Compartment Page 8149 Seat Position Sensor: Testing and Inspection SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: ON-VEHICLE INSPECTION 1. CHECK SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If there are any defects as mentioned below, replace the seat position sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. CAUTION: For removal and installation procedures of the seat position sensor, be sure to follow the correct procedure. Page 4127 Ultrasonic Sensor (for Front Side) Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Front Side) Components PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): COMPONENTS Page 3589 (d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. (e) Check if any DTCs have been stored. Note down any DTCs. (f) Clear DTCs See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. (g) Check if the MIL goes off. OK: MIL goes off. NG -- CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) OK -- REPAIR CIRCUITS INDICATED BY OUTPUT DTCS See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Engine Control System - SFI System 3. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) (a) Disconnect the ECM connector. (b) Turn the ignition switch to ON. (c) Check that the MIL is not illuminated. OK: MIL is not illuminated. NG -- CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) OK -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal 4. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) Child Restraint Seat Anchor Bracket (for Double Cab) Child Restraint: Service and Repair Child Restraint Seat Anchor Bracket (for Double Cab) Components SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Double Cab): COMPONENTS Removal SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Double Cab): REMOVAL 1. REMOVE REAR SEAT ASSEMBLY Page 1406 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Locations Oxygen Sensor Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 5424 Control Module: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 8230 (2) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. Page 1745 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Components Engine Temperature Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: COMPONENTS Page 8463 Alarm Module: Service and Repair Installation THEFT DETERRENT: THEFT WARNING ECU: INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR ECU (a) Install the ECU with the nut. (b) Install the junction block with the 2 nuts. (c) Connect the connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 3. INSTALL INSTRUMENT SIDE PANEL LH Page 9023 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 1627 Page 6306 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 559 Heated Glass Element Relay: Locations Window Defogger System WINDSHIELD / WINDOWGLASS: WINDOW DEFOGGER SYSTEM: PARTS LOCATION Page 4160 Page 8163 Air Bag Control Module: Diagrams Page 2723 Removal 1UR-FE EXHAUST: EXHAUST PIPE (for Regular Cab Standard Deck): REMOVAL CAUTION: * Wear protective gloves when removing the exhaust pipe. * The exhaust pipe is extremely hot immediately after the engine has stopped. * Confirm that the exhaust pipe has cooled down before removing it. 1. REMOVE TAILPIPE ASSEMBLY (a) Remove the bolt, clamp and gasket. (b) Disconnect the tailpipe from the exhaust pipe support. 2. REMOVE CENTER EXHAUST PIPE ASSEMBLY (a) Remove the 4 bolts. (b) Disconnect the center exhaust pipe from the 3 exhaust pipe supports. (c) Remove the center exhaust pipe from the front exhaust pipe and front No. 3 exhaust pipe. Page 9121 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 1215 SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Page 5947 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. Page 5948 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 1688 *: for 5 leaf spring Standard Caster Inclination for Regular Cab of Standard Deck Page 1064 Removal LIGHTING: REAR DOOR COURTESY SWITCH: REMOVAL HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. 1. REMOVE REAR DOOR COURTESY SWITCH (a) Remove the bolt. Page 8799 Speaker: Service and Repair Front Door Speaker (for CrewMax) Components AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): COMPONENTS Page 1321 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 8526 (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY Page 8131 Seat Occupant Classification Module - Air Bag: Service and Repair Installation SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: INSTALLATION 1. INSTALL OCCUPANT CLASSIFICATION ECU (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Attach the claw and install the occupant classification ECU to the seat. NOTICE: * If the ECU has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the ECU, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the ECU. 2. INSTALL FRONT SEAT ASSEMBLY RH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. Page 6991 Relay Box: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 8367 (a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the battery in place. (b) Connect the cable to the positive (+) battery terminal. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): COMPONENTS Page 3317 NG -- REPLACE RELAY OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 4. INSPECT ECM (IGSW VOLTAGE) (a) Disconnect the ECM connectors. (b) Turn the ignition switch to ON. (c) Measure the voltage according to the value(s) in the table below. Page 6842 Page 2812 (a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE OK -- Continue to next step. 2. INSPECT RELAY (IG2, EFI) (a) Remove the integration relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 9018 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 1131 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 1977 Engine Room R/B, J/B - Engine Compartment Left Page 8091 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 6586 Auxiliary Power Outlet: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Locations Headlamp Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Diagrams Alarm System Transponder: Diagrams 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 1367 Air Bag Deactivation Switch: Service and Repair Curtain Shield Airbag Cutoff Switch Components SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Disconnect the connector. Page 689 (2) If the result is not as specified, replace the outer mirror switch. 3. INSPECT OUTER MIRROR SWITCH ASSEMBLY (w/ Memory) (a) Inspect the outer mirror switch. (1) Select "L" on the left/right adjustment switch. (2) Measure the resistance according to the value(s) in the table below. Standard resistance: (3) If the result is not as specified, replace the outer mirror switch. (4) Select "R" on the left/right adjustment switch. (5) Using an ohmmeter, measure the resistance and check the results in accordance with the value(s) in the table below. Standard resistance: Page 7024 *: for 5 leaf spring Standard Wheel Angle for Regular Cab of Standard Deck Page 6323 AJ9-JI2 Page 5790 Parking Brake Warning Switch: Service and Repair Reassembly PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY 1. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the switch with the screw. Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf) Locations Steering Column Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Locations Four Wheel Drive Selector Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 1830 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 5605 BRAKE CONTROL: BRAKE ACTUATOR: INSTALLATION NOTICE: In case of replacing the skid control ECU, perform the zero point calibration of the steering angle sensor, master cylinder pressure sensor, and yaw rate and deceleration sensor See: Testing and Inspection/Programming and Relearning 1. INSTALL VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY (a) Install the VSC actuator with actuator bracket with the 3 nuts. NOTICE: Do not drop the actuator. If dropped, replace it. (b) Tighten the 3 nuts uniformly in alphabetical order. Torque : 22 Nm (224 kgf-cm, 16 ft-lbf) 2. CONNECT BRAKE TUBE (a) Set each brake line to the correct position on the brake actuator as shown in the illustration. HINT * *1: FR RH * *2: FR LH * *3: RR RH * *4: RR LH * *5: FR Master Cylinder * *6: RR Master Cylinder (b) Install a new clamp onto the VSC actuator bracket. (c) Using a union nut wrench, connect the 4 brake tubes. Torque : 15 Nm (155 kgf-cm, 11 ft-lbf) NOTICE: Component Tests and General Diagnostics Acceleration/Deceleration Sensor: Component Tests and General Diagnostics BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION 1. CHECK YAW RATE SENSOR (a) Check the yaw rate sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 5627 Traction Control Relay: Testing and Inspection BRAKE CONTROL: STOP LIGHT CONTROL RELAY: ON-VEHICLE INSPECTION 1. CHECK STOP LIGHT CONTROL RELAY (a) Remove the stop light control relay from the engine room relay block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) If the result is not as specified, replace the relay. (d) Install the stop light control relay. Power Source Control ECU Power Distribution Module: Diagrams Power Source Control ECU Page 6465 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 5271 Removal PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): REMOVAL 1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY Page 1085 Headlamp Alignment Switch: Service and Repair Removal LIGHTING: HEADLIGHT LEVELING SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE HEADLIGHT LEVELING SWITCH (a) Detach the 2 claws and remove the switch. Page 9168 1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from front to back using the pry bar to assist. Be careful NOT to damage the chrome/painted surface. 2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and hammer to punch the plastic bits into the tube. Use an air gun to blow the posts out through the end of the tube. 3. Discard the step pad. 4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard. 5. Install the new post retainers into the holes in the tube. 6. Line up the replacement step posts with the holes in the post retainers. 7. Using the palm of your hand push firmly down in all post locations. Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly. Page 2683 Thermostat: Service and Repair Removal 1UR-FE COOLING: THERMOSTAT: REMOVAL HINT If the thermostat was not installed, cooling efficiency would decrease. Even if the engine tends to overheat, do not remove the thermostat. 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. DRAIN ENGINE COOLANT See: Coolant/Service and Repair 3. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 4. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Removal 5. REMOVE AIR TUBE SUB-ASSEMBLY LH (a) Disconnect the 2 connectors. (b) Disconnect the water by-pass hose. (c) Disconnect the 2 wire harness clamps and air hose. (d) Remove the bolt and disconnect the air tube LH from the water inlet housing. (e) Disconnect the vacuum sensor connector and clamp. (f) Remove the 2 bolts and disconnect the air hose from the air switching valve LH. (g) Remove the air tube LH. 6. DISCONNECT OUTLET RADIATOR HOSE (a) Disconnect the radiator hose. 7. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT (a) Remove the 3 nuts, water inlet with thermostat and gasket. Page 5200 (l) If the boots are stretched or contracted, correct them. (m)Install the inboard joint boot clamps in the same manner as the outboard side. HINT Adjust the clearance of the inboard joint boot clamps. Standard clearance: 6. INSPECT FRONT DRIVE SHAFT ASSEMBLY See: Testing and Inspection/Component Tests and General Diagnostics/Front Drive Shaft Assembly Disassembly AXLE: REAR AXLE SHAFT: DISASSEMBLY 1. REMOVE REAR AXLE SHAFT SNAP RING (a) Using a snap ring expander, remove the snap ring. 2. REMOVE REAR AXLE SHAFT (a) Using SST and a press, press out the rear axle shaft. SST : 09521-25011 SST : 09521-60010 (b) Remove the rear axle bearing inner retainer from the axle hub. (c) Remove the rear axle shaft washer from the axle hub. Page 6532 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Procedures Seat Belt: Procedures Front Seat Outer Belt Assembly (for CrewMax) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): DISPOSAL HINT When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in accordance with the procedures described below. If any abnormality occurs during activation of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a front seat outer belt that has a non-activated pretensioner. * The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to nearby people. * When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (32.8 ft.) away from the front seat outer belt. * Use gloves and safety glasses when handling a front seat outer belt with an activated pretensioner. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. * Perform procedures in a place away from electrical interference. * When activating the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). 1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery to activate the seat belt pretensioner. (a) Check if SST is functioning properly. SST : 09082-00700 CAUTION: When activating the seat belt pretensioner, always use the specified SST. Page 660 Power Door Lock Switch: Locations Wireless Door Lock Control System DOOR LOCK: WIRELESS DOOR LOCK CONTROL SYSTEM: PARTS LOCATION Page 3328 (c) WAVEFORM 2: HINT The wavelength varies in accordance with the engine operating conditions. (d) WAVEFORM 3: HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the heated oxygen sensor. (e) WAVEFORM 4: Page 2985 Power Steering Pressure Switch: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: REMOVAL 1. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DRAIN POWER STEERING FLUID 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the power steering oil pressure switch connector. (b) Remove the power steering oil pressure switch. (c) Remove the O-ring. Page 1922 Fluid - Differential: Fluid Type Specifications Differential Oil Type ........................................................................................................................ Toyota Genuine Differential Gear Oil LT 75W-85 GL-5 or equivalent Page 9034 Trailer Connector: Electrical Diagrams Trailer Towing Part 1 Page 2948 Manifold Pressure/Vacuum Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSPECTION 1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Check the resistance. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the manifold absolute pressure sensor. Page 7189 (a) Remove the bolt and separate the pressure feed tube. (b) Remove the gasket. 8. REMOVE VANE PUMP ASSEMBLY (a) Remove the 2 bolts and vane pump assembly. Installation POWER STEERING: VANE PUMP (for 1UR-FE): INSTALLATION 1. INSTALL VANE PUMP ASSEMBLY HINT Before performing the following procedures, move the spacer until the vane pump can be installed. (a) Install the vane pump with the 2 bolts. Torque : 28 Nm (286 kgf-cm, 21 ft-lbf) 2. CONNECT PRESSURE FEED TUBE Page 2764 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 5037 (b) If the bearing is damaged during removal, replace it. 19. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using a brass bar and hammer, tap out the bearing (outer race). (b) If the bearing is damaged during removal, replace it. 20. REMOVE DIFFERENTIAL RING GEAR (a) Place matchmarks on the ring gear and differential case. (b) Remove the 12 ring gear set bolts. (c) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case. 21. INSPECT REAR DIFFERENTIAL CASE ASSEMBLY RUNOUT HINT If the ring gear runout is within the specified value (see "INSPECT RUNOUT OF DIFFERENTIAL RING GEAR" procedure), this inspection is not necessary. (a) Install the differential case to the differential carrier. (b) Inspect the differential case runout. Locations Cargo Lamp Relay: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 4145 Page 9102 Components Tire Pressure Monitor Receiver / Transponder: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS Page 393 HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor. (b) WAVEFORM 1: Page 3091 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 8319 Air Bag Deactivation Switch: Testing and Inspection Curtain Shield Airbag Cutoff Switch SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: INSPECTION 1. INSPECT CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 2852 Fuel Pump Control Unit: Locations Double Cab Body Page 1888 Page 2686 (e) Connect the 2 wire harness clamps. HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration. (f) Connect the water by-pass hose and 2 connectors. HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration. 4. ADD ENGINE COOLANT See: Coolant/Service and Repair 5. INSPECT FOR COOLANT LEAK See: Testing and Inspection 6. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Installation 7. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 8. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 465 (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 3801 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 3452 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 8960 Parking Assist Switch: Service and Repair Removal PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE DRIVE MONITOR SWITCH (a) Detach the 2 claws and remove the monitor switch. Page 1929 Fluid - Transfer Case: Fluid Type Specifications Transfer Oil Type ..................................................................................................................................................... ....................................... Gear oil API GL-4 or GL-5 Recommended viscosity ................................... ................................................................................................................................................ SAE 75W-90 Page 5194 Axle Shaft Assembly: Overhaul Disassembly DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): DISASSEMBLY 1. REMOVE INBOARD JOINT BOOT CLAMP (a) Using a side cutter, cut the 2 inboard joint boot clamps and remove them. 2. DISCONNECT INBOARD JOINT BOOT (a) Disconnect the inboard joint boot from the inboard joint shaft. 3. REMOVE INBOARD JOINT SHAFT (a) Place matchmarks on the inboard joint shaft and outboard joint shaft. NOTICE: Do not punch the marks. (b) Using a screwdriver, remove the snap ring from the outboard joint shaft. (c) Remove the inboard joint shaft from the outboard joint shaft. (d) Place matchmarks on the outboard joint shaft, inner race and cage. NOTICE: Do not punch the marks. (e) Remove the 6 balls. (f) Slide the cage to the outboard joint side. (g) Using a snap ring expander, remove the snap ring. Page 6961 Page 6801 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Cylinder Head Gasket (for Bank 1) Cylinder Head Gasket: Service and Repair Cylinder Head Gasket (for Bank 1) Components 1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 1): COMPONENTS Removal 1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 1): REMOVAL 1. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Remove the exhaust manifold LH See: Exhaust System/Exhaust Manifold/Service and Repair/Removal. 2. REMOVE CAMSHAFTS (for Bank 1) (a) Remove the camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Camshaft (for Bank 1)/Removal. 3. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY (a) Remove the 16 valve rocker arms from the cylinder head. HINT Arrange the removed parts in the correct order. 4. REMOVE VALVE LASH ADJUSTER ASSEMBLY (a) Remove the 16 valve lash adjusters from the cylinder head. HINT Arrange the removed parts in the correct order. 5. REMOVE VALVE STEM CAP (a) Remove the 16 valve stem caps from the cylinder head. HINT Arrange the removed parts in the correct order. 6. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Page 8784 Speaker: Testing and Inspection Front Door Speaker (for Double Cab) AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSPECTION 1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 10 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. 3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Diagrams Vacuum Brake Booster: Diagrams Page 8122 Page 3549 resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR BRANCH WIRE) (a) Disconnect the A17 skid control ECU with actuator connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE SKID CONTROL ECU BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU WITH ACTUATOR - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 8671 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 6278 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 9037 Trailer Towing Part 4 Page 3482 2. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU) (a) Disconnect the J2 main body ECU connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH ACTUATOR) A -- Continue to next step. 3. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (MAIN BODY ECU) OK -- REPLACE MAIN BODY ECU 4. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A17 skid control ECU with actuator connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR) Rear Oil Seal Seals and Gaskets: Service and Repair Rear Oil Seal Components JF1A TRANSFER: TRANSFER CASE REAR OIL SEAL: COMPONENTS Replacement JF1A TRANSFER: TRANSFER CASE REAR OIL SEAL: REPLACEMENT 1. DRAIN TRANSFER OIL See: Fluid - Transfer Case/Service and Repair Page 6321 Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Floor Shift] AJ1-TJ1 Page 1349 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Page 5734 Hydraulic Control Assembly - Antilock Brakes: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6529 Push the terminal retainer down to the temporary lock position. Symptom Related Diagnostic Procedures Drive/Propeller Shaft: Symptom Related Diagnostic Procedures PROPELLER SHAFT: PROPELLER SHAFT SYSTEM: PROBLEM SYMPTOMS TABLE HINT Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Page 7689 (a) Remove the bolt and disconnect the discharge hose from the cooler condenser. NOTICE: * When removing the bolt, do not allow any tools to contact the pipe. * When removing the bolt, hold a part of the pipe near the connector. (b) Remove the O-ring from the discharge hose. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. 7. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (a) Remove the 2 bolts and air conditioning tube and accessory from the cooler condenser. NOTICE: * When removing the bolt, do not allow any tools to contact the pipe. * When removing the bolt, hold a part of the pipe near the connector. (b) Remove the O-ring from the air conditioning tube and accessory. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them. 8. REMOVE COOLER CONDENSER ASSEMBLY (a) Remove the 2 bolts. (b) Remove the cooler condenser, as shown in the illustration. 9. REMOVE COOLER DRYER Page 8984 Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Column Shift Type) Components THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): COMPONENTS Removal THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH Page 1849 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 5151 4. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Disassembly 5. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Disassembly 6. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal. SST : 09308-10010 7. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 8. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Disassembly 9. REMOVE FRONT DIFFERENTIAL CASE See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Disassembly 10. REMOVE DIFFERENTIAL DRIVE PINION See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Disassembly 11. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Disassembly 12. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER 13. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer. 14. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION 15. INSTALL FRONT DIFFERENTIAL CASE 16. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 17. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING See: Differential Carrier/Service and Repair/Overhaul/Front Differential Carrier Assembly/Reassembly 18. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 19. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a hammer, tap in a new oil seal. Page 8343 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 5124 D. Fill the bracket with Loctite 5040 (or equivalent) until sealant can be seen coming out of the bracket opening. Allow sealant to setup for 12 minutes. E. Inspect surrounding area for damage. 2. Test drive the vehicle to confirm the repair. Page 8581 Replacement/Rear Bumper (for Resin Type Bumper)/Installation 7. INSTALL REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 8. INSTALL REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 9. INSTALL REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 10. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 11. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 12. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation 13. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 7369 (b) Temporarily install the shock absorber, cushion and retainer with the nut. (c) Temporarily install the lower side of the shock absorber with the bolt and nut. 2. STABILIZE SUSPENSION (a) Lower the vehicle. (b) Press down on the vehicle several times to stabilize the suspension. 3. TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH (a) Tighten the bolt and 2 nuts. Upper side - Torque : 28 Nm (286 kgf-cm, 21 ft-lbf) Lower side - Torque : 90 Nm (918 kgf-cm, 66 ft-lbf) 4. INSTALL REAR WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 5. REMOVE SAFETY STANDS Disposal SUSPENSION: REAR SHOCK ABSORBER: DISPOSAL 1. DISPOSE OF SHOCK ABSORBER ASSEMBLY REAR Page 3095 Ignition Switch: Connector Views Locations Overdrive Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Locations Shift Interlock Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 3398 (1) The branch wire is a wire harness which diverges from the main wire to an ECU or sensor. (c) Termination circuits (1) The termination circuits is a circuit which converts the communication current of the CAN communication into the bus voltage. It consists of a resistor and condenser. 2 termination circuits are necessary on a bus. (d) CAN J/C (1) The CAN J/C is designed so that it can be used with CAN communication which has a termination circuit and CAN communication which does not have a termination circuit. 3. CIRCUIT DESCRIPTION (a) The V bus and MS bus each have termination circuits with 120 Ohms x 2 of resistance. High speed communication at 500 kbps and 250 kbps is possible. 4. ECU OR SENSOR WHICH COMMUNICATE VIA CAN COMMUNICATION SYSTEM HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU * *4: w/ Seat Memory (a) ECM (b) Skid control ECU with actuator (c) Combination meter ECU (d) Center airbag sensor (e) Air conditioning amplifier (f) Steering angle sensor (g) Bus buffer ECU*1 (h) 4WD control ECU*2 (i) Main body ECU (j) Power steering ECU*3 (k) Front power seat ECU and switch LH*4 (l) Outer mirror control ECU*4 (m)Multiplex tilt and telescopic ECU*4 5. DIAGNOSTIC CODES FOR CAN COMMUNICATION SYSTEM (a) DTCs for the CAN communication system are as follows: U0073, U0100, U0114, U0123, U0124, U0126, U0129, U0199, U0208, U1002, U1115, B1499, and B2621 6. NOTES REGARDING TROUBLESHOOTING (a) Trouble in the CAN bus (communication line) can be checked through the DLC3 (except when there is a wire break other than in the branch wire of the DLC3). NOTICE: Do not connect the tester directly to the DLC3. Be sure to use a service wire. (b) DTCs regarding the CAN communication system can be checked using the Techstream. Page 8366 (b) Loosen the nut, move the stay off the battery, and remove the battery. 3. REMOVE FRONT AIRBAG SENSOR (a) Remove the nut and front airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Connect the connector. (d) Install the front airbag sensor with the nut. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the front airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (e) Check that there is no looseness in the installation parts of the front airbag sensor. 2. INSTALL BATTERY Page 685 Service and Repair Fuel Pressure Release: Service and Repair 1UR-FE FUEL: FUEL SYSTEM: PRECAUTION CAUTION: * Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. * Do not smoke or be near an open flame when working on the fuel system. * Keep gasoline away from rubber and leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures. (1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. (2) Put a container under the connecting part of the pressure line. (3) Slowly loosen the connection. (4) Disconnect the connection. (5) Plug the connection with a rubber plug. (b) Observe these precautions when removing and installing the injectors: Page 8369 Locations Actuator: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Diagrams Brake Fluid Level Sensor/Switch: Diagrams Page 6007 Battery: Specifications SERVICE SPECIFICATIONS: 1UR-FE CHARGING: SERVICE DATA Page 279 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 3571 Information Bus: Tools and Equipment CAN Communication PREPARATION: CAN COMMUNICATION: RECOMMENDED TOOLS Page 4516 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 904 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSPECTION 1. INSPECT AMBIENT TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NOTICE: * Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. * When measuring the resistance, the sensor temperature must be the same as the ambient temperature. HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the ambient temperature sensor. Page 5672 Yaw Rate Sensor: Service and Repair Installation BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION 1. INSTALL YAW RATE SENSOR (a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of the sensor bracket. (b) Install the yaw rate sensor with the 2 nuts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * Make sure that the sensor is oriented correctly. * If the sensor is dropped, replace it. * Securely connect the connector. * When installing the sensor, make sure to avoid impacts to the sensor. 2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation 3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration See: Testing and Inspection/Programming and Relearning. 6. CHECK YAW RATE SENSOR SIGNAL (a) Check the yaw rate sensor signal See: Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 1712 (c) * for 5 leaf spring Standard caster inclination (unloaded vehicle): for Regular Cab of Standard Deck Page 6901 Symbols Used Within Diagrams Symbols Used Within Diagrams Components Parking Assist Control Module: Service and Repair Components PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: COMPONENTS Page 9252 Up to 11/2009 ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): DISASSEMBLY REAR DOOR TRIM BOARD SUB-ASSEMBLY LH 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel. Page 9069 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Components Engine Temperature Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: COMPONENTS Page 6603 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 6298 J/B No.5 - Instrument Panel Center Page 5759 16. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3700 mm [12 ft. 1.7 in.] Wheelbase Type) (a) Remove the adjustment nut and lock nut (labeled A). (b) Remove the bolt (labeled B) and cable retainer. (c) Remove the 2 nuts (labeled C) and 2 clamps from the body. (d) Disconnect the 2 clamps (labeled D) from the No. 1 parking brake cable. (e) Remove the 2 bolts (labeled E) and No. 1 parking brake cable from the inside of the vehicle. NOTICE: Do not bend and twist the parking brake cable. (f) Remove the 3 bolts (labeled F) and No. 1 cable support bracket. Page 8806 4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE FRONT DOOR ARMREST COVER LH 6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 4 screws and speaker. NOTICE: Do not touch the cone part of the speaker. 9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) (a) Remove the 3 screws and speaker with bracket. (b) Detach the 3 claws and remove the speaker from the bracket. NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. Page 8278 Removal SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. REMOVE REAR SEAT ASSEMBLY (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal Page 9224 Page 308 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 4903 4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 7. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 8. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 9. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 10. REMOVE LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 11. REMOVE UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 12. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 13. REMOVE COLUMN SHIFT ASSEMBLY (a) Move the shift lever to N. (b) Disconnect the column shift transmission control cable end from the column shift. (c) Disconnect the connector and detach the harness clamp. Page 1936 Engine Oil: Fluid Type Specifications Grade ................................................................................................................................................... ..................................... ILSAC multigrade engine oil 4.6L V8 ................................................................................................................................................ ............................................................... SAE 0W-20 5.7L V8 ................................................................................................................................................ .............................................. SAE 5W-20 or 0W-20 Page 8052 NOTICE: Do not turn the spiral cable with steering sensor by the airbag wire harness. (d) Rotate the spiral cable with steering sensor clockwise approximately 2.5 turns to align the marks. NOTICE: Do not turn the spiral cable with spiral sensor by the airbag wire harness. HINT The spiral cable with steering sensor will rotate approximately 2.5 turns to both the left and right from the center. 5. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 6. INSTALL STEERING PAD See: Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 7. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 8. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. INSPECT STEERING PAD See: Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 7774 (a) Install the evaporator to the blower case (front side). (b) Install the blower case (back side). (c) Install the 6 screws and attach the 4 claws. (d) Install the packing, as shown in the illustration. 4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY Locations Tire Pressure Sensor: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 3494 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU) OK -- Continue to next step. 12. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR) (a) Disconnect the J83 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR) OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR 13. CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU) (a) Disconnect the J28 combination meter ECU connector. Components Power Distribution Module: Service and Repair Components OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS Initial Inspection and Diagnostic Overview Shifter A/T: Initial Inspection and Diagnostic Overview SHIFT LEVER ASSEMBLY (for Column Shift Type) A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. INSPECT SHIFT LEVER POSITION (a) When moving the shift lever from P to R with the ignition switch ON and the brake pedal depressed, make sure that it moves smoothly and correctly into position. (b) Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D and moves in reverse after moving the shift lever to R. If the operation cannot be performed as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition. SHIFT LEVER ASSEMBLY (for Floor Shift Type) A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. INSPECT SHIFT LEVER POSITION (a) When moving the shift lever from P to R with the ignition switch ON and the brake pedal depressed, make sure that it moves smoothly and correctly into position. (b) Check that the shift lever does not stop when moving the shift lever from R to P, and check that the shift lever does not stick when moving the shift lever from D to S. (c) Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D and moves in reverse after moving the shift lever to R. If the operation cannot be performed as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition. Page 5028 Page 7813 Control Module HVAC: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 6501 Relay Box: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Page 8297 The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel will then determine the applicable part number and place an order through Dealer Daily. The dealership service department will complete the Seat Belt Extender Customer Information Label attached to the part and review the "Owner Instructions" with the customer. The dealership should give a copy of the completed worksheet and Owner Instructions to the customer and keep the originals in the customer's file. To assure utmost owner satisfaction, it is recommended that dealerships designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper fitting to individual customers. This bulletin contains the following information: ^ Procedure and Sample Label ^ Application Charts Page 3735 HINT The wavelength becomes shorter as the vehicle speed increases. (k) WAVEFORM 10: HINT The duty ratio varies depending on the throttle actuator operation. (l) WAVEFORM 11: HINT The duty ratio varies depending on the throttle actuator operation. (m)WAVEFORM 12: Page 5463 Page 8663 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 4401 Fuel Gauge Sender: Diagrams Page 6918 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 3786 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 6823 Front Door Wire Page 8655 Symbols Used Within Diagrams Symbols Used Within Diagrams Engine Controls - ECM Update For Shift Performance Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift Performance T-SB-0285-10 October 12, 2010 ECM Calibration: Enhancement to Shifting Performance Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction Some vehicles may exhibit the following shifting conditions: ^ Harsh shift on acceleration below 20 mph during the 2-1 downshift. ^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as "busy shifting". The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has been revised. Use the following repair procedure to address these conditions. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Locations Four Wheel Drive Selector Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 9311 Lower Side Moulding / Trim: Service and Repair Removal EXTERIOR: SIDE MOULDING: REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * When removing the moulding, heat the vehicle body and moulding using a heat light. Standard heating temperature: NOTICE: Do not heat the vehicle body and moulding excessively. 1. REMOVE LOWER NO. 1 SIDE PANEL MOULDING LH (a) Detach the 2 clips and remove the moulding. Page 6378 Page 5386 Page 6334 Page 1270 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Page 4123 Page 8485 Hood Sensor/Switch (For Alarm): Diagrams Page 4619 Knock Sensor: Diagrams Page 3277 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 4371 (m)Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (o) Stop the engine. (p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Standard fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or higher (q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and carefully remove SST and the fuel tube connector to prevent gasoline from spraying. (s) Reconnect the fuel tube (fuel tube connector). (t) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. Page 2967 Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION 1. INSPECT AIR FUEL RATIO SENSOR (a) Disconnect the 2 sensor connectors. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the air fuel ratio sensor. (d) Connect the 2 sensor connectors. Locations Steering Column Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 7654 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 8377 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Engine - Controls - Non-Linear Acceleration From A Stop PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Controls Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 6594 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 5017 Actuator: Service and Repair Installation DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): INSTALLATION 1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator. (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the differential tube as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent HINT Install the actuator within 10 minutes of applying seal packing. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the actuator onto the differential tube. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (g) Install the 4 bolts. Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) (h) Connect the actuator hose. (i) Connect the actuator connector. 2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and Inspection/Component Tests and General Diagnostics/Touch Select 2-4 and High-Low System. Page 6808 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 5888 Steering Angle Sensor: Service and Repair Installation BRAKE CONTROL: STEERING ANGLE SENSOR: INSTALLATION 1. INSTALL STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 2. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 3. INSTALL UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 4. INSTALL LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 5. ADJUST SPIRAL CABLE See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 7. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 8. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 9. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 6812 Page 3375 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Up to 11/2009 Brake Fluid Pump Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 3361 Page 1930 Fluid - Transfer Case: Testing and Inspection JF1A TRANSFER: TRANSFER OIL: ON-VEHICLE INSPECTION 1. CHECK TRANSFER OIL (a) Remove the filler plug and gasket. (b) Check that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole. (c) If the result is not as specified, add transfer oil. Oil grade: GL-4 or GL-5 Viscosity: SAE 75W-90 Standard capacity: 1.1 +/- 0.06 liters (1.2 +/- 0.06 US qts, 1.0 +/- 0.05 Imp. qts) NOTICE: * After changing the oil, drive the vehicle and check the oil level again. * Too much or too little oil will lead to transfer problems. (d) When the oil level is too low, check for oil leak. (e) Install a new gasket into the filler plug and then tighten the plug. 2. ADD TRANSFER OIL (a) Remove the filler plug and gasket. (b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the case plug (for filler) hole. NOTICE: * When adding oil, pour it slowly. * Add oil a little at a time, waiting several minutes between each addition of oil. (c) Wait approximately 5 minutes and check that the oil level has not changed. (d) Install a new gasket and the filler plug. Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) Up to 11/2009 Hose/Line HVAC: Service and Repair Up to 11/2009 AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS Page 463 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 2647 Radiator Cooling Fan: Service and Repair Installation 1UR-FE COOLING: FAN: INSTALLATION 1. INSTALL FAN (a) Install the fan to the fluid coupling with the 4 nuts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. INSTALL FAN SHROUD (a) Install the fan pulley to the fan bracket. (b) Place the fan shroud together with the fluid coupling fan between the radiator and engine. NOTICE: Be careful not to damage the radiator core (c) Temporarily install the fluid coupling fan to the fan bracket with the 4 nuts. Tighten the nuts as much as possible by hand. (d) Attach the shroud's claws to the radiator as shown in the illustration. (e) Install the shroud with the 2 bolts. Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf) (f) w/ Trailer Towing System: (f) Pass the 2 hoses through the flexible hose clamp and close the clamp as shown in the illustration. (g) Connect the reservoir hose to the upper radiator tank. (h) Install the fan and generator V-belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. (i) Tighten the 4 nuts of the fluid coupling fan. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) Page 1431 (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 6409 Page 5132 D. Fill the bracket with Loctite 5040 (or equivalent) until sealant can be seen coming out of the bracket opening. Allow sealant to setup for 12 minutes. E. Inspect surrounding area for damage. 2. Test drive the vehicle to confirm the repair. Page 4542 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Components Tire Pressure Warning Reset Switch: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS Page 891 Page 2994 Transmission Position Switch/Sensor: Diagrams Page 8316 Air Bag Deactivation Switch: Diagrams Curtain Airbag Cutoff Switch Page 2715 Page 5527 Transmission Speed Sensor: Testing and Inspection A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION 1. INSPECT SPEED SENSOR NT (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. 2. INSPECT SPEED SENSOR SP2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. Page 2314 (b) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. (c) Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration. NOTICE: Uniformly loosen the bolts while keeping the camshaft level. (d) Remove the 6 bearing caps. HINT Arrange the removed parts in the correct order. (e) Remove the No. 1 and No. 2 camshafts. 13. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH (a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. HINT Tape the screwdriver tip before use. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. Installation 1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): INSTALLATION 1. INSTALL CAMSHAFT BEARING CAP RH Page 5908 Wheel Speed Sensor: Diagrams Rear Speed Sensor Body/Frame - Choppy Ride Condition Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Choppy Ride Condition T-SB-0369-10 December 23, 2010 Choppy Ride (Tundra D-Cab Short Bed) Service Category Suspension Section Rear Suspension Market USA Applicability Introduction Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road conditions. A newly designed cab mount has been developed to help improve this condition. NOTE 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 occurrence of the specified condition described in this bulletin. Front Door Courtesy Switch Door Switch: Testing and Inspection Front Door Courtesy Switch LIGHTING: FRONT DOOR COURTESY SWITCH: INSPECTION 1. INSPECT FRONT DOOR COURTESY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 2717 (d) Remove the 2 gaskets from the front exhaust pipes. 3. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 4. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Removal 5. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (a) Disconnect the air fuel ratio sensor connector. (b) Remove the 3 nuts. (c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support to remove it. (d) Remove the gasket. 6. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Removal 7. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Disconnect the air fuel ratio sensor connector. (b) Remove the 3 nuts and the front exhaust pipe from the exhaust manifold RH. (c) Remove the gasket. 8. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Using SST, remove the sensor. SST : 09224-00010 9. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Air Fuel Ratio Sensor/Removal 10. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 1) Page 6553 J/B No.3 - Instrument Panel Right Testing and Inspection Fuel Filler Cap: Testing and Inspection 1UR-FE EMISSION CONTROL: FUEL TANK CAP: INSPECTION 1. INSPECT FUEL TANK CAP ASSEMBLY (a) Visually check if the cap and/or gasket are deformed or damaged. (b) If the result is not as specified, replace the fuel tank cap assembly or gasket. Page 3840 Oxygen Sensor: Diagrams Heated Oxygen Sensor Components Steering Angle Sensor: Service and Repair Components BRAKE CONTROL: STEERING ANGLE SENSOR: COMPONENTS Locations Ignition Relay: Locations MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 7772 (c) Remove the blower case (back side). (d) Remove the evaporator from the blower case (front side). 16. REMOVE NO. 1 COOLER THERMISTOR (a) Remove the No. 1 cooler thermistor. 17. REMOVE COOLER EXPANSION VALVE (a) Using a 4 mm hexagon wrench, remove the 2 bolts. (b) Remove the tube and accessory and 2 O-rings. (c) Remove the cooler expansion valve and 2 O-rings from the cooler evaporator. Reassembly Page 8730 4. Refer to the applicable model and model year in the table for part replacement. 5. Register the new XM Receiver Radio Identification Number (RID). A. Be prepared with the VIN OLD Radio Identification Number (RID) and NEW Radio Identification Number (RID). B. Call the XM Radio Listener line at 1-800-967-2346. C. Provide the necessary information and the representative will complete the request. D. If the customer has an active account confirm XM Satellite Radio service has been refreshed and the radio is active. Once you can listen to channels 4, 11, and 41 you know the activation was successful. Page 8685 (c) Low power mode: (1) If a garage door opener switch is held for 100 seconds or more, the garage door opener will enter low power mode to economize on power consumption. When the garage door opener has entered low power mode, the LED turns off. Page 3372 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 75 (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT The procedures listed below are for the LH side. 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL FRONT DOOR SCUFF PLATE RH (a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT The procedures listed below are for the LH side. Page 341 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 9305 1. Heat the double-sided tape remaining on the body with an infrared lamp or equivalent. HINT: 1. Heat the tape to 40 to 60 degrees C for approximately 1 to 2 minutes. 2. Wipe off the remaining double-sided tape using a clean cloth or equivalent. HINT: 1. If a name plate is installed without thoroughly removing the remaining double-sided tape from the body, the name plate will not adhere Page 6377 Removal and Replacement Axle Shaft Assembly: Removal and Replacement Components DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): COMPONENTS Page 7590 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 5101 5. Replace the affected oil baffle. A. Using a double nut configuration remove 2 axle housing stud bolts to allow the oil baffle to be removed. See Figures 3 and 4 and attached video below for reference. B. Use a 10 mm 1.25 thread chaser or cleaner to carefully clean the axle housing threads. NOTICE After cleaning the axle housing threads be sure to thoroughly clean out the axle housing of any debris to prevent damage to the differential assembly. C. Replace the oil baffle and fully seat the new baffle against the upper and lower tabs. See Figure 5 for reference. D. Using a double nut configuration install the new axle housing stud bolts until they are fully seated. Torque: 36 N*m (373 kgf*cm, 27 ft*lbf) 6. Install the rear differential and axle shafts. Take special care not to damage the oil baffle or axle seals when installing the axle shaft assembly. Refer to TIS applicable model year Tundra Repair Manual: 7. Test drive the vehicle and confirm proper operation. Page 3413 Page 4659 Page 8283 6. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 7. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 8. INSTALL REAR SEAT ASSEMBLY (a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Crewmax LH Side)/Installation. Components SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): COMPONENTS Page 1752 (4) for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector. (5) for Fuel Hose Connector Cover Type: Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration. (6) Check that there is no fuel leakage. 3. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See: Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection. Page 8834 Page 2041 Driver Side J/B Inner Circuit Page 3234 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 5917 (e) Attach the 3 clips (labeled F). NOTICE: * When installing the clips, do not twist the wire harness. * When installing the clips, securely insert them as shown in the illustration. (f) Connect the speed sensor connector (labeled G). NOTICE: Securely connect the connector. 7. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 3240 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 5414 Four Wheel Drive Selector Switch: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE 4WD CONTROL SWITCH (a) Detach the 3 claws to remove the switch. Page 4528 (4) Connect the engine wire harness clamp. 3. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts. Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Tighten the hose clamp. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) (c) Connect the ventilation hose and vacuum hose. (d) Connect the MAF meter connector and clamp. 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 6637 (a) for AC Power Supply: Connect the clamp. (b) Install the bezel with the 4 screws. 5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly Page 7707 21. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 22. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 24. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Check Mode Procedure. Page 1822 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. Components Control Module HVAC: Service and Repair Components AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: COMPONENTS Page 289 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 3833 Applicable Vehicles Page 8144 Seat Occupant Sensor: Diagrams Rear Occupant Classification Sensor Page 7188 POWER STEERING: VANE PUMP (for 1UR-FE): REMOVAL 1. REMOVE RADIATOR ASSEMBLY (a) Remove the radiator assembly See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal. 2. DRAIN POWER STEERING FLUID 3. SEPARATE HARNESS BRACKET (a) Remove the bolt and separate the bracket. 4. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE (a) Detach the clip and disconnect the hose. 5. DISCONNECT POWER STEERING OIL PRESSURE SENSOR CONNECTOR (a) Disconnect the oil pressure sensor connector. 6. DISCONNECT SOLENOID VALVE CONNECTOR (a) Disconnect the solenoid valve connector. 7. SEPARATE PRESSURE FEED TUBE Page 822 Traction Control Switch: Service and Repair Installation BRAKE CONTROL: VSC OFF SWITCH: INSTALLATION 1. INSTALL VSC OFF SWITCH (a) Attach the 2 claws to install the VSC OFF switch into the lower instrument panel finish panel LH. (b) Connect the VSC OFF switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Page 8805 Removal AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly Page 3030 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Components Brake Pedal Assy: Service and Repair Components BRAKE: BRAKE PEDAL: COMPONENTS Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Page 2359 Standard Bearing Center Wall Thickness: Other Journals: Main Bearing Clearance, Standard & Limit Page 3629 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection Page 6541 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 4719 Four Wheel Drive Selector Switch: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE 4WD CONTROL SWITCH (a) Detach the 3 claws to remove the switch. Page 5600 Hydraulic Control Assembly - Antilock Brakes: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Locations Tire Pressure Warning Reset Switch: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 3117 SST : 09268-31012 90467-13001 95336-08070 09268-41500 09268-41120 SST : 09268-45014 09268-41200 09268-41220 (g) Wipe off any gasoline. (h) Reconnect the cable to the negative (-) battery terminal. (i) Operate the fuel pump. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. NOTICE: Do not start the engine. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (j) Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (k) If the pressure is higher than the specification, replace the fuel pressure regulator. If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator assembly. (l) Start the engine. Page 1500 Ignition Switch: Testing and Inspection 1UR-FE STARTING: IGNITION SWITCH: INSPECTION 1. INSPECT IGNITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the ignition switch assembly. Page 787 Braking Sensor/Switch: Diagrams Page 178 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. Page 4037 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 2559 Page 5735 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection BRAKE CONTROL: BRAKE ACTUATOR: ON-VEHICLE INSPECTION 1. CONNECT TECHSTREAM (a) Connect the Techstream to the DLC3. (b) Start the engine and run it at idle. (c) Select the Active Test mode on the Techstream. HINT Refer to the Techstream operator's manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION (a) With the motor relay on, check the actuator motor operation noise. (b) Turn the motor relay off. (c) Depress the brake pedal and hold it for about 15 seconds. Check that the pedal does not go down any further while holding it. (d) With the motor relay on, check that the pedal could have pulsations. NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it consecutively, wait more than 20 seconds between each operation. (e) Turn the motor relay off and release the brake pedal. 3. INSPECT WHEEL OPERATION NOTICE: Never turn on a solenoid that is not described below. (a) With the brake pedal depressed, perform the following operations. (b) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) on simultaneously, and check that the pedal cannot be depressed. NOTICE: Do not keep the solenoid on for more than 10 seconds continuously. When operating it consecutively, wait more than 20 seconds between each operation. (c) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) off simultaneously, and check that the pedal can be depressed. (d) Turn the motor relay on and check that the pedal returns. NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it consecutively, wait more than 20 seconds between each operation. (e) Turn the motor relay off and release the brake pedal. (f) Using the procedure above, check the solenoids of the other wheels. HINT LEFT Front wheel LH: ABS Solenoid (SFLH), ABS Solenoid (SFLR) RIGHT Rear wheel RH: ABS Solenoid (SRRH), ABS Solenoid (SRRR) LEFT Rear wheel LH: ABS Solenoid (SRLH), ABS Solenoid (SRLR) (g) Clear the DTCs See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. Page 7768 (a) Remove the filter. 5. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (a) Remove the screw and duct. 6. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Remove the 2 screws and amplifier. 7. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY (a) Remove the 3 screws and motor. 8. REMOVE AIR DUCT (a) Remove the 2 screws and duct. 9. REMOVE DAMPER SERVO SUB-ASSEMBLY Diagrams Steering Angle Sensor: Diagrams Page 553 Control Module: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION 1. INSTALL 4WD CONTROL ECU (a) Install the ECU with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. Locations Power Distribution Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 7294 SST : 09631-20081 NOTICE: Be careful not to damage the control valve rings. (e) To prevent the control valve upper oil seal lip from getting damaged, wind vinyl tape around the serrated portion of the control valve. (f) Coat the control valve upper oil seal lip with power steering fluid. (g) Install the control valve onto the control valve housing. NOTICE: Be careful not to damage the control valve ring and control valve upper oil seal lip. (h) Apply grease to the needle roller bearing. (i) Install a new O-ring onto the control valve housing. (j) Wind vinyl tape around the serrated portion of the control valve. (k) Install the control valve w/ control valve housing onto the rack housing with the 2 bolts. Torque : 21 Nm (214 kgf-cm, 14 ft-lbf) 9. INSTALL STEERING GEAR RACK GUIDE (a) Install the rack guide. (b) Install the rack guide spring. (c) Apply adhesive to 2 or 3 threads of the rack guide spring cap. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (d) Provisionally install the rack guide spring cap. Components Variable Valve Timing Actuator Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS Page 2459 (e) Disconnect the purge line hose from the purge VSV. (f) Disconnect the vacuum switching valve connector (for ACIS). (g) Disconnect the vacuum hose. (h) Remove the bolt and disconnect the wire harness from the wire harness bracket. (i) Detach the 3 wire harness clamps from the 3 wire harness brackets. (j) Detach the 4 clamps from the fuel tube. (k) Disconnect the fuel tube from the fuel delivery pipe RH See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions. (l) Disconnect the fuel tube from the fuel delivery pipe LH See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions. (m)Remove the 2 nuts, 8 bolts, intake manifold and 2 gaskets. 8. REMOVE FUEL TUBE SUB-ASSEMBLY (a) Remove the bolt and fuel tube from the intake manifold. Components Crankshaft Main Bearing Seal: Service and Repair Components 1UR-FE ENGINE MECHANICAL: REAR CRANKSHAFT OIL SEAL: COMPONENTS Page 2763 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 1704 Standard difference: 0 +/-1 mm (0 +/-0.0394 in.) or less (e) Tighten the tie rod end lock nuts. Torque : 82 Nm (836 kgf-cm, 60 ft-lbf) (f) Place the boots on the seats and install the clips. HINT Make sure that the boots are not twisted. 5. INSPECT WHEEL ANGLE (a) Turn the steering wheel to the left and right full lock positions, and measure the turning angle. Standard wheel angle (unloaded vehicle): for Regular Cab of Standard Deck Standard wheel angle (unloaded vehicle): for Regular Cab of Long Deck Power Steering Oil Pressure Sensor Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor Components Variable Valve Timing Actuator Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS Page 3852 SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation Components Neutral Safety Switch: Service and Repair Components A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS Page 6912 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 5962 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 3374 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Components Thermostat: Service and Repair Components 1UR-FE COOLING: THERMOSTAT: COMPONENTS Page 6272 Push the terminal retainer down to the temporary lock position. Page 6617 Connectors Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. See: Locations Power Outlet [12V] Page 1076 Hazard Warning Switch: Service and Repair Removal LIGHTING: HAZARD WARNING SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE HAZARD WARNING SWITCH (a) Detach the 2 claws and remove the switch. Page 5478 Actuator: Diagrams Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 3958 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 6181 HINT Tape the screwdriver tip before use. 10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 5. INSTALL POWER OUTLET SOCKET ASSEMBLY Drivetrain - Front End Grinding Noise In 4WD Differential Mount: All Technical Service Bulletins Drivetrain - Front End Grinding Noise In 4WD T-SB-0338-09 Rev1 September 16, 2009 Grinding Noise When in 4WD Service Category Drivetrain Section Axle/Differential Market USA Applicability March 10, 2010 Rev1: ^ Applicability has been updated to include 2008 - 2010 model year Sequoia vehicles. ^ Production Change Information has been added. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2008 - 2010 model year Sequoia and 2007 - 2010 model year Tundra vehicles may exhibit a grinding noise from the front of the vehicle while in 4WD. An updated differential support bolt is available to address this condition. Follow the repair procedure in this bulletin to inspect and replace the differential support bolt. 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 occurrence of the specified condition described in this bulletin. 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 7194 (a) Remove the front side plate from the front housing. (b) Using a screwdriver, remove the O-ring from the front side plate. HINT Tape the screwdriver tip before use. (c) Remove the O-ring from the front housing. 8. REMOVE VANE PUMP HOUSING OIL SEAL (a) Using a screwdriver and piece of cloth, pry out the oil seal. NOTICE: Be careful not to damage the front housing. Reassembly POWER STEERING: VANE PUMP (for 1UR-FE): REASSEMBLY NOTICE: When installing parts, coat the parts indicated by arrows with power steering fluid See: Removal and Replacement/Components 1. INSTALL VANE PUMP HOUSING OIL SEAL (a) Coat the lip of a new oil seal with power steering fluid. Page 3748 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 8869 Alarm Module: Diagrams Glass Breakage Sensor ECU Page 7643 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 6497 J/B No.4 - Instrument Panel Center Page 8840 (a) Attach the 4 clips and claw to install the speaker panel. 7. INSTALL FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 8. INSTALL FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): COMPONENTS Page 6229 Diode: Diagrams Diode (Starting) Page 2234 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 8810 CrewMax)/Removal 3. REMOVE BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE NO. 1 BOX SPEAKER ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts and box speaker. Installation AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSTALLATION 1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY (a) Install the box speaker with the 3 bolts. (b) Connect the connector. 2. INSTALL BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): COMPONENTS Page 2479 NOTICE: * Ensure that no oil is on the mounting surface of the cylinder head. * Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. HINT The cylinder head bolts are tightened in 3 progressive steps. (b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. (c) Step 1: (1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration. Torque : 36 Nm (367 kgf-cm, 27 ft-lbf) (d) Step 2: (1) Mark each cylinder head bolt head with paint as shown in the illustration. (2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1. (e) Step 3: (1) Tighten the cylinder head bolts an additional 90° in the sequence shown in step 1. (2) Check that the painted marks are now facing rearward. (f) Install and uniformly tighten the 2 bolts in the sequence shown in the illustration. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 5. INSTALL VALVE STEM CAP (a) Apply a light coat of engine oil to the valve stem caps. Locations Cruise Control Switch: Locations CRUISE CONTROL: CRUISE CONTROL SYSTEM: PARTS LOCATION Page 7077 Steering Column Control Module: Service and Repair Removal STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE UPPER STEERING COLUMN COVER (a) Remove the 2 screws. HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws. (b) Detach the 4 clips. (c) Detach the claw to remove the upper steering column cover. 3. REMOVE LOWER STEERING COLUMN COVER (a) Detach the 2 claws to remove the lower steering column cover. 4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal Page 6976 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 3067 Ignition Switch: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 4596 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 8606 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 occurrence of the specified condition described in this bulletin. Required Tools & Equipment Parts Information Repair Procedure Page 2397 (b) Remove the oil filter drain plug. (c) Install the pipe to the oil filter cap. HINT Use a container to catch the draining oil. NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe. (d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as shown in the illustration. (e) Using SST, remove the oil filter cap. SST : 09228-06501 NOTICE: Do not remove the oil filter bracket clip. Page 3522 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (POWER STEERING ECU) OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR 12. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR CENTER AIRBAG SENSOR) (a) Disconnect the J83 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Components Central Control Module: Service and Repair Components AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: COMPONENTS Page 6168 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 2421 Oil Filter: Service and Repair Replacement 1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT CAUTION: * Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. * Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents. * In order to protect the environment, used oil and used oil filters must be disposed of at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container. (c) Install a new gasket and the oil pan drain plug. Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) 2. REMOVE NO. 1 ENGINE UNDER COVER (a) Remove the 3 screws and 5 bolts. (b) Unhook the engine under cover from the vehicle body as shown in the illustration. 3. REMOVE OIL FILTER ELEMENT (a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe. Page 51 Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS Page 4658 Transfer Case Actuator: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 5648 Wheel Speed Sensor: Diagrams Front Speed Sensor Page 2617 (4) Connect the engine wire harness clamp. 3. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts. Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Tighten the hose clamp. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) (c) Connect the ventilation hose and vacuum hose. (d) Connect the MAF meter connector and clamp. 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 6540 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Locations Trailer Towing Relay: Locations Engine Room R/B, J/B - Engine Compartment Left Page 8356 Page 3363 Information Bus: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 2624 Water Pump: Testing and Inspection 1UR-FE COOLING: WATER PUMP: ON-VEHICLE INSPECTION 1. INSPECT WATER PUMP ASSEMBLY (a) Visually check the air hole and drain hole for coolant leakage. (b) If leakage is found, replace the water pump assembly. (c) Turn the pulley and check that the water pump bearing moves smoothly and quietly. (d) If necessary, replace the water pump assembly. Specifications Axle Nut: Specifications FRONT AXLE HUB NUT LH (for 4WD) Using a 39 mm socket wrench, install the hub nut. Torque.................................................................................................................................................. ...............................338 Nm (3446 kgf-cm, 249 ft-lbf) Page 8607 1. Please compare customer's iPod(TM) with the compatible models table listed below. If the customers' iPod(TM) is NOT listed, this TSB does NOT apply. 2. Verify the condition. NOTE If USB device error occurs during every use, visually inspect the port. 3. Verify the error condition continues when using a known good USB cable. 4. Replace the Multi-Media Interface ECU by following procedures in the Repair Manual. Page 2307 2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH (a) Install the valve rocker arms as shown in the illustration. (b) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.5 to 4.0 mm (0.138 to 0.157 in.) NOTICE: * Remove any oil from the contact surface. * Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. (c) Install the camshaft housing, and install the 18 bolts in the order shown in the illustration. for bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) except bolt A - Torque : 30 Nm (306 kgf-cm, 22 ft-lbf) NOTICE: * Do not start the engine for at least 2 hours after the installation. Page 8595 Rear Vision Camera: Service and Repair Installation PARK ASSIST / MONITORING: TELEVISION CAMERA: INSTALLATION HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL TELEVISION CAMERA ASSEMBLY (a) Attach the 3 clamps and install the television camera with the 2 bolts. (b) Connect the television camera connector. 2. INSTALL TAIL GATE SERVICE HOLE COVER See: Body and Frame/Tailgate/Service and Repair/Tail Gate/Installation 3. CHECK TELEVISION CAMERA ASSEMBLY ANGLE (a) Move the shift lever to R and check that the rear view image in the display has no lines or distortion and has good color. Page 1640 2. CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Jam Protection Function) (a) Remove the power window regulator master switch See: Service and Repair/Power Window Master Switch/Removal. (b) Reconnect the switch connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 1813 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 300 J/B No.5 - Instrument Panel Center Page 2417 Repair Procedure Page 6193 (a) for AC Power Supply: Connect the clamp. (b) Install the bezel with the 4 screws. 5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly Page 1687 for CrewMax of standard deck Page 8605 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Power Seat Switch (w/o Seat Position Memory System) Power Seat Switch: Service and Repair Power Seat Switch (w/o Seat Position Memory System) Components SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): COMPONENTS Page 9236 Page 3480 NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 3. CHECK INTEGRATION CONTROL AND PANEL ASSEMBLY (OPERATION) (a) Temporarily replace the integration control and panel assembly with a new or normally functioning one. (1) For Column Shift Type, refer to the following procedures See: Heating and Air Conditioning/Control Assembly/Service and Repair/Air Conditioning Panel (for Column Shift Type)/Removal. (2) For Floor Shift Type, refer to the following procedures See: Heating and Air Conditioning/Control Assembly/Service and Repair/Air Conditioning Panel (for Floor Shift Type)/Removal. (b) Check that the malfunction disappears. OK: Malfunction disappears. NG -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY See: Heating and Air Conditioning/Control Module HVAC/Service and Repair/Removal OK -- END (INTEGRATION CONTROL AND PANEL ASSEMBLY IS DEFECTIVE) Open In One Side of CAN Branch Line CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Open in One Side of CAN Branch Line - Open in One Side of CAN Branch Line DESCRIPTION If 2 or more ECUs and/or sensors do not appear on the Techstream's "CAN Bus Check" screen, one side of the CAN branch wire may be open. (One side of the CANH [branch wire]/CANL [branch wire] of the ECU and/or sensor is open.) HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU WIRING DIAGRAM Page 1004 Installation Procedure 1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover (2 places). 2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1 place). Page 2004 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 6020 NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn. (g) Remove SST 2 from the generator. (h) Turn SST 1-B, and remove SST 1-A and B. (i) Remove the pulley nut and pulley. 2. REMOVE GENERATOR REAR END COVER (a) Place the generator on the pulley. (b) Remove the 3 nuts and end cover. (c) Remove the terminal insulator. 3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY (a) Remove the 2 screws and brush holder. Page 328 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 4212 Page 4124 Page 3118 (m)Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (o) Stop the engine. (p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Standard fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or higher (q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and carefully remove SST and the fuel tube connector to prevent gasoline from spraying. (s) Reconnect the fuel tube (fuel tube connector). (t) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. Page 917 (a) Detach the 2 claws and remove the sensor. Page 226 Page 9393 5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount bolts. 6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be used in their place. Page 2450 Intake Manifold: Locations 1UR-FE INTAKE: INTAKE SYSTEM: PARTS LOCATION Page 9248 From 11/2009 ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): COMPONENTS Page 7879 Refrigerant Pressure Sensor / Switch: Diagrams Page 6936 Engine Room R/B, J/B - Engine Compartment Left Page 3533 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CONNECT CONNECTOR OK -- REPLACE NO. 1 JUNCTION CONNECTOR 5. CONNECT CONNECTOR (a) Reconnect the J94 No. 1 junction connector connector. NEXT -- Continue to next step. 6. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 2 JUNCTION CONNECTOR - ECM) (a) Disconnect the J113 No. 2 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CONNECT CONNECTOR OK -- Continue to next step. 7. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) (a) Measure the resistance according to the value(s) in the table below. Page 3116 Fuel Pressure: Testing and Inspection 1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. NOTICE: Do not start the engine. (c) Turn the Techstream main switch ON. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (e) Check the fuel pump operation. (1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard. If there is no sound, check the integration relay, fuel pump, ECM and wiring connector. (f) Check for fuel leak. (1) Check that there are no fuel leaks after performing maintenance anywhere on the system. If there are fuel leaks, repair or replace parts as necessary. 2. CHECK FUEL PRESSURE (a) Check that the battery voltage is 11 to 14 V. (b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Fuel Delivery and Air Induction/Service Precautions. (c) Disconnect the cable from the negative (-) battery terminal. (d) Remove the fuel pipe clamp from the fuel tube connector. (e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it. CAUTION: * Always read the precautions See: Fuel Delivery and Air Induction/Service Precautions before disconnecting the fuel tube connector (quick type). * The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. (f) Install SST (pressure gauge) as shown in the illustration. Page 4309 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 9131 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 4070 (f) Connect the connector. (g) Connect the wire harness clamp bracket with the nut. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 7575 Page 4910 1. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (a) Install the floor shift with the 4 bolts. Tighten the bolts in the order shown in the illustration. Torque : 14 Nm (143 kgf-cm, 10 ft-lbf) (b) Connect the transmission control cable to the shift lever retainer, and install a new clip. (c) Connect the control cable end to the shift lever. NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that the ridged side of the cable end is facing upward. (d) Connect the 2 connectors. 2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CONSOLE BOX CARPET 5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 5100 ^ Inspect the axles and rear differential axle housing oil baffles. ^ Install new rear differential axle housing oil baffle(s). ^ Reinstall rear axle shaft and differential and confirm proper operation. Repair Procedure 1. Test drive the vehicle and confirm the condition. Is the noise loudest from the rear of the vehicle? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. 2. Install ChassisEAR(TM) (or equivalent) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest from the rear differential area? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. 3. Remove the rear axle shafts and rear differential. Refer to the Technical Information System (TIS) applicable model year Tundra Repair Manual: 4. Inspect the rear axle housing oil baffles and axle shafts. Are the rear axle housing baffle(s) deformed or are there wear marks on the axle shaft(s) assembly? See Figures 1 and 2 for reference. ^ YES - Go to step 5. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 6958 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 1496 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Locations Transmission Temperature Sensor/Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Front Occupant Classification Sensor Seat Occupant Sensor: Diagrams Front Occupant Classification Sensor Page 6316 AJ9-JI2 Page 5849 Acceleration/Deceleration Sensor: Service and Repair Removal BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal 3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE YAW RATE SENSOR (a) Remove the 2 nuts (labeled A) and sensor. (b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the sensor bracket. Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 9032 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 307 Driver Side J/B Inner Circuit Page 3510 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU WITH ACTUATOR (CANH, CANL) OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal 16. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR) (a) Disconnect the J6 steering angle sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE SENSOR (CANH, CANL) OK -- REPLACE STEERING ANGLE SENSOR 17. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU) (a) Disconnect the J101 power steering ECU connector. Page 7736 (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 14. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Remove the 3 screws and plate. (b) Detach the 3 claws and remove the heater clamp. (c) Remove the heater radiator unit. 16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY Page 48 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL 1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Page 9209 Page 445 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY (a) Connect the 3 connectors. (b) Install the integration relay to the engine room relay block. (c) Install the engine room relay block cover. Page 4517 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 907 Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: REMOVAL 1. REMOVE AMBIENT TEMPERATURE SENSOR (a) Disconnect the connector. (b) Using a screwdriver, detach the clamp and remove the ambient temperature sensor. HINT Tape the screwdriver tip before use. Page 3493 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR) OK -- Continue to next step. 10. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - STEERING ANGLE SENSOR) (a) Disconnect the J87 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR) OK -- Continue to next step. 11. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - POWER STEERING ECU) NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)". (a) Disconnect the J115 No. 1 junction connector connector. Components Evaporator Temperature Sensor / Switch: Service and Repair Components AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: COMPONENTS Page 1467 Page 3815 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Page 278 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 8374 Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Diode (Starting) Starter Motor: Diagrams Diode (Starting) Center Airbag Sensor Assembly (for Column Shift Type) Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 5951 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 9003 Page 5409 Four Wheel Drive Selector Switch: Testing and Inspection JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION 1. INSPECT 4WD CONTROL SWITCH (a) Check the harness and connector (ECU - battery and body ground). (1) Measure the voltage and resistance according to the value(s) in the table below. Standard voltage: (2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning, repair or replace harness or connector. If the harness or connector is normal, replace the 4WD control ECU See: Control Module/Service and Repair/Removal. Standard resistance: (3) If there is a malfunction, repair or replace the harness or connector. (b) Check the harness and connector (switch - ECU). (1) Disconnect the A25 ECU connector. (2) Disconnect the L1 switch connector. (3) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 6359 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 9028 EFI Relay Fuel Pump Relay: Testing and Inspection EFI Relay 1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (EFI) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the EFI No. 1 fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the EFI No. 1 fuse. (b) Measure the resistance of the EFI relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 1034 Page 184 "Case2" 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 2615 (4) Remove the 2 bolts and disconnect the water by-pass pipe. (5) Remove the 4 bolts and 4 ignition coils. 4. REMOVE SPARK PLUG (a) Using a 16 mm plug wrench, remove the 8 spark plugs. Diagrams Amplifier: Diagrams Page 9214 Page 2638 Coolant: Service and Repair 1UR-FE COOLING: COOLANT: REPLACEMENT 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. DRAIN ENGINE COOLANT CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. HINT Collect the coolant in a container and dispose of it according to the regulations in your area. (a) Loosen the radiator drain cock plug. (b) Remove the radiator cap. Then drain the coolant from the radiator. (c) Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine. (d) Tighten the 2 cylinder block drain cock plugs. Torque : 13 Nm (130 kgf-cm, 9 ft-lbf) (e) Tighten the radiator drain cock plug by hand. 3. ADD ENGINE COOLANT (a) Add engine coolant. Standard Capacity: NOTICE: Do not substitute plain water for engine coolant. HINT TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids). LIN Communication System Information Bus: Description and Operation LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: SYSTEM DIAGRAM MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: SYSTEM DESCRIPTION 1. LIN COMMUNICATION SYSTEM DESCRIPTION * The LIN communication system is used for communication between the components below. * The LIN communication system has a component as a control master. (a) Window and Sliding Roof Components that Use LIN Communication Bus (for CrewMax) (1) Main Body ECU (Driver Side Junction Block)*1 (2) Power Window Regulator Master Switch Assembly*2 (3) Front Power Window Regulator Motor Assembly LH*2 (4) Front Power Window Regulator Motor Assembly RH*2 (5) Sliding Roof Drive Gear Sub-assembly (Sliding Roof ECU)*3 HINT * *1: Control master * *2: for Power Window Control System (w/ Jam Protection Function) * *3: w/ Sliding Roof System (b) Heater Components that Use LIN Communication (1) Air Conditioning Amplifier Assembly (A/C ECU)* HINT *: Control master (2) Integration Control and Panel Assembly 2. LIN COMMUNICATION SYSTEM DTCs The control master component shown below outputs LIN communication system DTCs when there is a malfunction in the LIN communication. If a LIN communication stops, the control master of that part of the LIN communication system outputs DTCs. (a) Main Body ECU (Driver Side Junction Block) Page 6090 Neutral Safety Switch: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the switch to the manual valve shaft. (b) Temporarily install the bolt. (c) Install a new lock washer and the nut. Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf) (d) Temporarily install the control shaft lever RH. (e) Turn the control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position. (f) Align the groove with the neutral basic line. Page 2399 (g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap. NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap. (h) Install the oil filter drain plug. Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Be careful that the O-ring does not get caught between any surrounding parts. 5. ADD ENGINE OIL (a) Add fresh oil. Standard Oil Grade (for USA): Standard Oil Grade (for Canada): Standard Oil Capacity: (b) Install the oil filler cap. 6. INSPECT FOR OIL LEAK (a) Start the engine. Make sure that there are no oil leaks from the area that was worked on. 7. CHECK ENGINE OIL LEVEL See: Testing and Inspection 8. INSTALL NO. 1 ENGINE UNDER COVER Page 2822 Page 9340 Front Fender Liner: Service and Repair Removal EXTERIOR: FENDER LINER (for Front Side): REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. REMOVE FENDER APRON MUDGUARD SEAL LH (a) for Steel Type Bumper: Remove the fender apron mudguard seal. (1) w/ Side Step: Remove the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and Replacement/Removal. (2) w/ Front Fender Mudguard: Remove the fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and Repair/Removal. (3) Remove the 18 clips and fender apron mudguard. (b) for Resin Type Bumper: Remove the fender apron mudguard seal. (1) w/ Side Step: Remove the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and Replacement/Removal. (2) w/ Front Fender Mudguard: Remove the fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and Repair/Removal. (3) Using a screwdriver, remove the pin hold clip. (4) Remove the 17 clips and fender apron mudguard. Page 3684 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 8024 Air Bag Deactivation Switch: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 8946 Removal PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT END PANEL LH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 3. REMOVE FRONT END PANEL RH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 4. REMOVE FRONT BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 7. REMOVE FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 8. REMOVE FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 9. REMOVE FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 10. REMOVE FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 11. REMOVE NO. 1 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. Page 4833 Required Tools & Equipment Important Information ^ 100,000 Mile Maintenance Interval - Inspection only; ATF-WS does NOT require any flushing or changing during the life of the vehicle. ^ The use of Genuine Toyota ATF-WS is recommended. ^ The use of additives or aftermarket fluids that are considered compatible or substitutes may result in shift concerns and damage to the internal transmission components. ^ ATF-WS is NOT compatible with T-IV or Dexron ATF. ^ Containers storing Toyota ATF-WS should ALWAYS be sealed - If exposed to the atmosphere, ATF-WS may absorb moisture and potentially cause shift concerns if used in operation. ^ One time use only. ^ When performing repairs on ATF-WS equipped transaxles, it is important to use only new, clean ATF-WS when refilling the ATM. ^ ATF-WS equipped ATMs may use the overflow type procedure - Any fluid drained from the overflow plug should be discarded following proper local regulations and never reused. Failure to do so could result in shift concerns and damage to the internal transmission components. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 1974 Engine Room R/B, J/B - Engine Compartment Left Page 5138 Fluid - Differential: Service and Repair DIFFERENTIAL: DIFFERENTIAL OIL: REPLACEMENT 1. DRAIN DIFFERENTIAL OIL (a) Stop the vehicle on a level place. (b) for Front Differential: (1) Using a 10 mm hexagon wrench, remove the filler plug and gasket. (2) Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil. (3) Using a 10 mm hexagon wrench, install a new gasket and the drain plug. Torque : 39 Nm (398 kgf-cm, 29 ft-lbf) (c) for Rear Differential: (1) Remove the filler plug and gasket. (2) Remove the drain plug and gasket, and drain the oil. (3) Install a new gasket and the drain plug. Torque : 49 Nm (500 kgf-cm, 36 ft-lbf) 2. ADD DIFFERENTIAL OIL (a) Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the differential filler plug hole. NOTICE: * Too much or too little oil will lead to differential problems. * After changing the oil, drive the vehicle and then check the oil level again. Oil type: Front differential capacity: Rear differential capacity: Page 6152 Push the terminal retainer down to the temporary lock position. Page 2706 12. REMOVE FRONT NO. 3 FLOOR HEAT INSULATOR (a) Remove the 4 nuts and front floor heat insulator. 13. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (a) Remove the 4 nuts and EGR pipe. (b) Remove the 2 gaskets. 14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (a) Remove the 3 bolts and heat insulator. 15. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Remove the 9 nuts, exhaust manifold and 2 gaskets. 16. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (a) Remove the 3 bolts and heat insulator. Page 3399 (c) The CAN communication system cannot detect trouble in the branch line of the DLC3 even though the DLC3 is also connected to the CAN communication system. 7. HOW TO DISTINGUISH CAN J/C CONNECTOR (a) In the CAN communication system, the shape of all connectors connected to the CAN J/C is the same. The connectors connected to the CAN J/C can be distinguished by the colors of the bus line and the connecting side of the connector. HINT See "TERMINALS OF ECU" See: Testing and Inspection/Pinout Values and Diagnostic Parameters/CAN Communication System for bus line color or the type of connecting surface. Page 2074 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 5651 (d) Remove the 3 bolts (labeled E), 3 harness clamps (labeled F) and sensor wire. 4. REMOVE FRONT SPEED SENSOR LH (a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the knuckle. 5. REMOVE FRONT SKID CONTROL SENSOR CLAMP LH (a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle. 6. REMOVE FRONT SKID CONTROL SENSOR WIRE RH (a) Disconnect the connector (labeled A) from the front speed sensor. (b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C). Page 5060 (a) Check that the differential case is not damaged. If the differential case is damaged, replace it. 24. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING (a) Using a brass bar and hammer, tap out the 2 bearings. 25. REMOVE DIFFERENTIAL CLUTCH HUB (a) Using a snap ring expander, remove the snap ring. (b) Remove the differential clutch hub. 26. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, tap out the oil seal. SST : 09308-00010 27. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH (a) Using a snap ring expander, remove the snap ring. (b) Using a plastic-faced hammer, tap out the side gear shaft. Locations Hood Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 8690 Integrated Accessory Switch Assembly: Testing and Inspection METER: DRIVE MONITOR SWITCH: INSPECTION 1. INSPECT DRIVE MONITOR SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (a) If the result is not as specified, replace the monitor switch. (b) Inspect the switch illumination. (1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 6 (ILL-). (2) Check that the light comes on. OK: LED comes on. (3) If the result is not as specified, replace the monitor switch. Page 8824 3. INSTALL FRONT DOOR ARMREST COVER LH 4. INSTALL COURTESY LIGHT ASSEMBLY (w/ Power Window) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 6. INSTALL FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): COMPONENTS Page 2937 Knock Sensor: Diagrams Page 7593 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 7479 Tire Pressure Module: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL NOTICE: * It is necessary to perform initialization See: Testing and Inspection/Programming and Relearning/Initialization after registration See: Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. * When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU using the intelligent tester or Techstream and write them down before removal. 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the ECU connector. (b) Remove the 2 nuts and ECU. Page 5919 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE REAR WHEEL 3. REMOVE REAR SPEED SENSOR LH (a) Disconnect the speed sensor connector (labeled A). (b) Remove the nut (labeled B) and speed sensor (labeled C). 4. REMOVE REAR SPEED SENSOR RH (a) Disconnect the speed sensor connector (labeled A). (b) Remove the nut (labeled B) and speed sensor (labeled C). 5. REMOVE SKID CONTROL SENSOR WIRE (a) Disconnect the sensor connector (labeled A). (b) Detach the 7 clips (labeled B). (c) Remove the bolt (labeled C). (d) Remove the nut (labeled D) and skid control sensor wire. Installation BRAKE CONTROL: REAR SPEED SENSOR: INSTALLATION Page 6266 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 7688 Condenser HVAC: Service and Repair Removal AIR CONDITIONING: CONDENSER: REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 3. REMOVE FRONT BUMPER COVER (a) for Steel Type Bumper: Remove front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal. (b) for Resin Type Bumper: Remove front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal. 4. DISCONNECT OIL COOLER HOSE (w/ Air Cooled Transmission Oil Cooler) (a) Using pliers, grip the claws of the clip and slide the clip. (b) Disconnect the 2 oil cooler hoses. 5. REMOVE RADIATOR ASSEMBLY (a) for 1GR-FE: Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal. (b) for 1UR-FE: Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal. (c) for 3UR-FE: Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal. (d) for 3UR-FBE: Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal. 6. DISCONNECT DISCHARGE HOSE Page 6237 Engine Room R/B, J/B - Engine Compartment Left Page 1436 Seat Belt Buckle Switch: Diagrams Page 1924 (b) for Rear Differential: (1) Install a new gasket and the filler plug. Torque : 49 Nm (500 kgf-cm, 36 ft-lbf) (c) for Front Differential: (1) Using a 10 mm hexagon wrench, install a new gasket and the filler plug. Torque : 39 Nm (398 kgf-cm, 29 ft-lbf) Page 9406 Grille: Overhaul Disassembly EXTERIOR: RADIATOR GRILLE: DISASSEMBLY 1. REMOVE RADIATOR GRILLE (OR FRONT PANEL) EMBLEM (a) Detach the 3 claws and remove the radiator grille (or front panel) emblem. 2. REMOVE RADIATOR GRILLE PROTECTOR (a) Remove the radiator grille protector. Reassembly EXTERIOR: RADIATOR GRILLE: REASSEMBLY HINT When installing the radiator grille protector, heat the radiator grille surface using a heat light. Standard: NOTICE: Do not heat the radiator grille excessively. 1. INSTALL RADIATOR GRILLE PROTECTOR (a) Clean the radiator grille sub-assembly surface. (1) Using a heat light, heat the radiator grille sub-assembly surface. (2) Remove the double-sided tape from the radiator grille sub-assembly surface. (3) Wipe off any tape adhesive residue with cleaner. (b) Install a new radiator grille protector. Page 1327 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 1214 (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. Page 3535 D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal A -- REPLACE ECM 10. CONNECT CONNECTOR (a) Reconnect the J84 No. 1 junction connector connector. NEXT -- Continue to next step. 11. CHECK FOR OPEN IN CAN BUS MAIN WIRE (COMBINATION METER ECU - NO. 1 JUNCTION CONNECTOR) (a) Disconnect the J28 combination meter ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU (COMBINATION METER ECU - NO. 1 JUNCTION CONNECTOR) OK -- REPLACE COMBINATION METER ASSEMBLY Air Conditioning Amplifier Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Air Conditioning Amplifier Communication Stop Mode - Air Conditioning Amplifier Communication Stop Mode DESCRIPTION WIRING DIAGRAM Page 499 (a) Attach the claw to install the upper steering column cover. (b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish panel. (c) Install the 2 screws. Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf) HINT Turn the steering wheel to the right and left as necessary to install the 2 screws. 8. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 9166 Refer to the service kit instruction sheet for further detail. Page 8223 (3) Move SST at least 10 m (32.8 ft.) away from the front of the vehicle. (4) Close all the doors and windows of the vehicle. HINT Leave a gap in one of the windows for inserting SST wire harness. NOTICE: Take care not to damage SST wire harness. (5) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the negative (-) terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (32.8 ft.) of the vehicle. (2) Press SST activation switch to activate the seat belt pretensioner. HINT The seat belt pretensioner operates at the same time SST activation switch's LED illuminates. (f) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: * Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. * Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. HINT When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated front seat outer belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) CAUTION: Be sure to follow the procedures listed below when activating the seat belt pretensioner. (a) Remove the front seat outer belt. (1) Wind the seat belt with the retractor. (2) When the seat belt is sufficiently wound, cut the seat belt approximately 100 mm (3.94 in.) from the retractor, as shown in the illustration. HINT The seat belt is designed so that winding the seat belt before pretensioner activation will decrease the pulling power of the seat belt during pretensioner activation. Page 1851 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 1304 Page 6370 Page 2025 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 1144 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Page 706 Page 1405 Impact Sensor: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 1444 Seat Occupant Sensor: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 6352 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Components Traction Control Switch: Service and Repair Components BRAKE CONTROL: VSC OFF SWITCH: COMPONENTS Page 4074 Leak Detection Pump: Diagrams Page 3520 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (MAIN BODY ECU) OK -- Continue to next step. 9. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - SKID CONTROL ECU WITH ACTUATOR) (a) Disconnect the A46 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Page 4955 (a) Disconnect the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose from the cooler condenser. (b) Remove the bolt and No. 2 oil cooler tube together with the 2 oil cooler hoses. (c) Remove the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose from the No. 2 oil cooler tube. 9. REMOVE OIL COOLER TUBE (w/ Trailer Towing System) (a) Remove the 2 bolts and oil cooler tube. Page 6931 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 2932 Engine Temperature Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm ball joint lock nut wrench, remove the sensor. (c) Remove the gasket from the sensor. Page 3261 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 4083 (a) Connect the No. 8 water by-pass hose. HINT The direction of the hose clamp is indicated in the illustration. 6. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY (a) Install the No. 3 water by-pass pipe with the 2 bolts and connect the hose. HINT The direction of the hose clamp is indicated in the illustration. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the No. 4 water by-pass hose. 7. INSTALL INTAKE MANIFOLD ASSEMBLY (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Page 7014 Auxiliary Power Outlet Switch: Service and Repair Removal OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INVERTER MAIN SWITCH (a) Detach the 2 claws and remove the main switch. Page 936 (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. 11. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 screws and damper servo. 12. REMOVE BLOWER CASE SUB-ASSEMBLY (a) Remove the 3 screws. (b) Detach the 2 claws and remove the case. 13. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY Locations Accessory Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Components Variable Valve Timing Actuator Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS Page 5106 Actuator: Diagrams Page 4792 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 2639 (b) Slowly pour coolant into the radiator reservoir until it reaches the FULL line. (c) Install the reservoir cap. (d) Press the inlet and outlet radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant. (e) Install the radiator cap. (f) Start the engine and warm it up until the thermostat opens. HINT The thermostat opening timing can be confirmed by pressing the radiator inlet hose by hand, and checking when the engine coolant starts to flow inside the hose. (g) Maintain the engine speed at 2000 to 2500 rpm. NOTICE: * Make sure that the radiator reservoir still has some coolant in it. * Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature. * If there is not enough coolant, the engine may burn out or overheat. * Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the FULL line. * Run the engine at 2000 rpm until the coolant level has stabilized. (h) Press the inlet and outlet radiator hoses several times by hand to bleed air. CAUTION: * Wear protective gloves. * Be careful as the radiator hoses are hot. * Keep your hands away from the fan. (i) Stop the engine, and wait until the engine coolant cools down to ambient temperature. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (j) Check that the coolant level is between the FULL and LOW lines. If the coolant level is below the LOW line, repeat all of the procedures above. If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines. 4. INSPECT FOR COOLANT LEAK See: Testing and Inspection 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 2119 (h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for work that can be finished quickly. Safety stands must be used to support the vehicle. Page 8250 (c) Detach the 7 clips and 2 claws, and remove the pillar garnish. 8. REMOVE CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 9. REMOVE FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the nut and shoulder anchor. (b) Disconnect the pretensioner connector as shown in the illustration. (c) Remove the 2 bolts and seat belt. Installation SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT SEAT OUTER BELT ASSEMBLY Page 388 Page 7866 (a) Remove the packing. (b) Remove the 6 screws and detach the 4 claws. (c) Remove the blower case (back side). (d) Remove the evaporator from the blower case (front side). 17. REMOVE NO. 1 COOLER THERMISTOR (a) Remove the No. 1 cooler thermistor. Page 7084 Steering Control Module: Diagrams Fuel System - Fuel Sending Unit Upper Cover Replacement Fuel Gauge Sender: Technical Service Bulletins Fuel System - Fuel Sending Unit Upper Cover Replacement T-SB-0399-09 December 23, 2009 Fuel Sending Unit Upper Cover Installation Service Category Engine/Hybrid System Section Fuel System Market USA Applicability Introduction A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010 MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair Manual by providing the installation procedures and part number details for this component. Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit Upper Cover. Production Change Information This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 2665 (c) Remove the drain cock plug. (d) Remove the O-ring. Page 6354 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 192 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 3966 6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may set. Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control valves if necessary: 7. If there is NO liquid found in the air pump assemblies or the DTC is still present after replacement inspect the air injection system. Refer to TIS 2010 model year Tundra Repair Manual: 8. Clear the DTC and road test the vehicle to confirm the condition has been corrected. Page 8477 Alarm System Transponder: Service and Repair Installation ENGINE IMMOBILISER: TRANSPONDER KEY AMPLIFIER: INSTALLATION 1. INSTALL TRANSPONDER KEY AMPLIFIER (a) Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined. (b) Push the transponder key amplifier and install it to the upper bracket. NOTICE: Do not push the amplifier upward with excessive force. 2. INSTALL LOWER STEERING COLUMN COVER (a) Attach the 2 claws to install the lower steering column cover. (b) Install the 2 screws. Removal and Replacement Shifter A/T: Removal and Replacement Components A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): COMPONENTS Locations Transmission Speed Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 4312 ^ 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 7455 Tire Pressure Warning Reset Switch: Diagrams Page 4406 Fuel Gauge Sender: Service and Repair Fuel Sending Unit Cover Fuel Sending Unit Upper Cover Installation Introduction A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010 MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair Manual by providing the installation procedures and part number details for this component. Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit Upper Cover. Production Change Information This information applies to vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change Information (Continued) Parts Information Warranty Information Page 7363 (a) Remove the nut and bolt from the shock absorber lower side. NOTICE: To prevent the shock absorber with coil spring from falling, leave the bolt inserted. (b) Remove the 4 nuts. (c) Remove the bolt (lower side) and shock absorber with coil spring. Installation SUSPENSION: FRONT SHOCK ABSORBER: INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. TEMPORARILY INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING (a) Temporarily install the upper side of the shock absorber to the chassis frame with the 4 nuts. (b) Temporarily install the lower side of the shock absorber to the lower suspension arm with the bolt, washer and nut. 2. STABILIZE SUSPENSION (a) Lower the vehicle. Page 686 Power Mirror Switch: Diagrams Page 2422 (b) Remove the oil filter drain plug. (c) Install the pipe to the oil filter cap. HINT Use a container to catch the draining oil. NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe. (d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as shown in the illustration. (e) Using SST, remove the oil filter cap. SST : 09228-06501 NOTICE: Do not remove the oil filter bracket clip. Specifications Alignment: Specifications SERVICE SPECIFICATIONS: SUSPENSION: SERVICE DATA Stanard Vehicle Height for Regular Cab of Standard Deck for Regular Cab of Long Deck for Double Cab of Standard Deck Page 3219 Page 2281 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 6834 Page 8961 Parking Assist Switch: Service and Repair Installation PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSTALLATION 1. INSTALL DRIVE MONITOR SWITCH (a) Attach the 2 claws to install the monitor switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Locations Temperature Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Initial Inspection and Diagnostic Overview Neutral Safety Switch: Initial Inspection and Diagnostic Overview A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ON-VEHICLE INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Apply the parking brake and turn the ignition switch to ON. (b) Depress the brake pedal and check that the engine starts when the shift lever is in N or P, but does not start when the shift lever is in other positions. (c) Check that the back-up light illuminates and the reverse warning buzzer sounds when the shift lever is in R, but do not function when the shift lever is in other positions. Page 9304 Page 8814 Removal AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Disassembly Page 2101 J/B No.6 Assembly Inner Circuit Page 6535 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 2084 Relay Box: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 4605 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transmission Fluid Capacities: With tow package: 2WD ..................................................................................................................................................... .......................................................... 12.3 qt (11.6L) 4WD ................................................................. .............................................................................................................................................. 11.9 qt (11.3L) Without tow package: 2WD ..................................................................................................................................................... .......................................................... 11.7 qt (11.7L) 4WD ................................................................. .............................................................................................................................................. 11.4 qt (10.8L) Locations Temperature Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 2604 (3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. (4) Pinch the connector and disconnect the connector and pipe. (5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out. NOTICE: Do not use any tools. (6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. (7) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag. (e) Observe these precautions when connecting the fuel tube connector (for Quick Type). (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe. (3) After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected. Page 4008 (4) Check that air flows from port A to port B. If the result is not as specified, replace the air switching valve. Diagrams Shift Interlock Solenoid: Diagrams Page 2720 Install the monolithic converter protector within the angle range specified in the illustration. 5. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Install the sensor to the No. 2 exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 6. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Air Fuel Ratio Sensor/Installation 7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (b) Connect the air fuel ratio sensor connector. 8. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Installation 9. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (a) Connect the front No. 2 exhaust pipe to the exhaust pipe support. (b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts. Page 4438 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 2097 Driver Side J/B Inner Circuit Page 5637 Traction Control Switch: Service and Repair Removal BRAKE CONTROL: VSC OFF SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE VSC OFF SWITCH (a) Disconnect the VSC OFF switch connector. (b) Using a screwdriver, detach the 2 claws and remove the VSC OFF switch from the lower instrument panel finish panel LH. Page 2709 for nut A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) except nut A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (a) Install the heat insulator with the 3 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 5. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (a) Install 2 new gaskets. (b) Install the EGR pipe with the 4 nuts, and tighten the nuts in the sequence shown in the illustration. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 6. INSTALL FRONT NO. 3 FLOOR HEAT INSULATOR (a) Install the front floor heat insulator with the 4 bolts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) 7. INSTALL FRONT NO. 4 FLOOR HEAT INSULATOR (a) Install the front floor heat insulator with the 4 bolts. Page 805 Steering Angle Sensor: Programming and Relearning BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION PERFORM INITIALIZATION OF STEERING ANGLE SENSOR NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will become misaligned. (a) Check that the steering wheel is in the centered position. (b) Disconnect the negative battery terminal for more than 2 seconds. NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. (c) Reconnect the negative battery terminal. Page 7159 Tire Pressure Warning Reset Switch: Testing and Inspection TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION 1. CHECK TIRE PRESSURE WARNING RESET SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 1172 Engine Temperature Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the sensor. (b) Using a 19 mm ball joint lock nut wrench, install the sensor. Torque : 20 Nm (200 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench See: Service Precautions (c) Connect the sensor connector. 2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 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 6368 Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 5279 *1: for 5 leaf spring *2: includes Off road package * If the measured angle is not within the specification, adjust it with the bearing washer (See "Adjust Propeller Shaft Angle"). (b) Measure the No. 2 joint angle. (1) Using SST, measure and record the angle of the propeller shaft (D). SST : 09370-50010 (2) Subtract the angle of the propeller shaft (D) from the angle of the intermediate shaft (C) to calculate the No. 2 joint angle. No. 2 joint angle: Page 6631 Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Column Shift Type) Components OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Removal OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab) Page 7891 Solar Sensor: Service and Repair Installation AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSTALLATION 1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Connect the connector. (b) Attach the 2 claws to install the sensor. 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. Page 6644 (a) Disconnect the connector. (b) Using a screwdriver, detach the 5 claws and remove the console box bezel. HINT Tape the screwdriver tip before use. 3. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 4. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. Page 3507 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU) OK -- Continue to next step. 12. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR) (a) Disconnect the J83 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR) Page 2061 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 5344 Transmission Position Switch/Sensor: Diagrams Recall - Floor Mat/Accelerator Pedal Interferance Technical Service Bulletin # SSC90L Date: 091001 Page 7630 Page 104 Brake Fluid Pump Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Locations Ignition Relay: Locations MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 492 Steering Column Control Module: Diagrams Page 2319 (b) RH: (1) Using a wrench to hold the hexagonal portion of the No. 1 camshaft, tighten the camshaft timing gear with the bolt. Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf) (2) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear with the bolt. Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf) 13. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and Repair/Overhaul/Reassembly 14. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (a) Install the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Installation. 15. INSPECT IGNITION TIMING See: Testing and Inspection/Engine 16. INSPECT ENGINE IDLE SPEED See: Testing and Inspection/Engine Page 2799 ^ 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 5595 Electronic Brake Control Module: Diagrams Page 174 Heated Oxygen Sensor Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE INSPECTION 1. CHECK HEATED OXYGEN SENSOR (a) Disconnect the heated oxygen sensor connector. (b) Measure the heater resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the heated oxygen sensor. (d) Connect the heated oxygen sensor connector. Page 605 Removal PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 3. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal Page 5758 (a) for Regular Cab Standard Deck: Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. (b) except Regular Cab Standard Deck: Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal. 13. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FE) (a) for Regular Cab Standard Deck: Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal. (b) except Regular Cab Standard Deck: Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal. 14. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FBE) (a) except Regular Cab Standard Deck: Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal. 15. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3220 mm [10 ft. 6.8 in.] Wheelbase Type) (a) Remove the adjustment nut and lock nut (labeled A). (b) Remove the bolt (labeled B) and cable retainer. (c) Remove the nut (labeled C) and clamp from the body. (d) Disconnect the clamp (labeled D) from the No. 1 parking brake cable. (e) Remove the 2 bolts (labeled E) and No. 1 parking brake cable from the inside of the vehicle. NOTICE: Do not bend and twist the parking brake cable. (f) Remove the 3 bolts (labeled F) and No. 1 cable support bracket. Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 876 Cruise Control Switch: Service and Repair Installation CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: INSTALLATION 1. INSTALL CRUISE CONTROL MAIN SWITCH (a) Install the switch, as shown in the illustration. (b) Install the 2 screws. (c) Connect the connector. 2. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 3. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 4. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 5. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Service and Repair Cabin Air Filter: Service and Repair Step 1. Turn the engine switch off. Step 2. Open the glove box. Step 3. Remove the tray. Page 4588 "Case2" 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 8614 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 8095 (a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the battery in place. (b) Connect the cable to the positive (+) battery terminal. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): COMPONENTS Page 3182 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Page 3299 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 7971 * The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag. * Do not apply water to a front seat side airbag with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the front seat side airbag from the tire. (2) Place the front seat side airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Page 6591 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 4434 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay 1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION 1. REMOVE FUEL PUMP RELAY (F/PMP) (a) Remove the fuel pump relay from the engine room relay block. 2. INSPECT FUEL PUMP RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the fuel pump relay. 3. INSTALL FUEL PUMP RELAY (a) Install the fuel pump relay to the engine room relay block. Page 5296 09954-04010 09957-04010 09958-04011 SST : 09955-04100 NOTICE: Pull out the spider bearing until the SST claws contact the shaft's universal joint yoke. (h) Clamp the protruding universal joint spider bearing in a vise. (i) Using a brass bar and hammer, tap the shaft yoke to remove the universal joint spider bearing. NOTICE: Do not tap the shaft tube. HINT Use the same removal procedure for the universal joint spider bearing on the opposite side. (j) Using SST, pull out the universal joint spider bearing from the flange yoke. SST : 09331-60010 SST : 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 Page 6376 Floor Wire Page 6238 Engine Room R/B, J/B - Engine Compartment Left Page 4246 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 8141 Page 3088 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 5050 0.05 to 0.95 mm (0.00197 to 0.0374 in.) HINT Connect 2 SST with vinyl tape. (b) Coat the lip of the oil seal with MP grease. 23. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, install the companion flange. SST : 09950-30012 09951-03010 09953-03010 09954-03010 09956-03030 SST : 09955-03050 24. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Coat the threads of a new nut with hypoid gear oil. (b) Using SST to hold the companion flange. SST : 09330-00021 09330-00030 (c) Tighten the nut until the standard preload is reached. Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less) (d) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Locations Shift Interlock Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 6463 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. Page 8076 NOTICE: * If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the front airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (e) Check that there is no looseness in the installation parts of the front airbag sensor. 2. INSTALL BATTERY (a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the battery in place. (b) Connect the cable to the positive (+) battery terminal. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 2707 17. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Remove the 9 nuts, exhaust manifold and 2 gaskets. Page 4067 Evaporative Emission Control Canister: Service and Repair Removal 1UR-FE EMISSION CONTROL: CANISTER: REMOVAL 1. REMOVE CANISTER ASSEMBLY (a) Remove the nut and disconnect the wire harness clamp bracket. (b) Disconnect the connector. (c) Disconnect the purge line hose. (d) Disconnect the air inlet line hose. (1) Push the hose firmly toward the canister side. (2) Pinch the hose (portion A) as shown in the illustration. (3) Pull out the hose. NOTICE: * Do not use any tools in this procedure. * Check for any dirt and foreign matter contamination in the canister and around the hose. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the canister and hose. (e) Disconnect the vent line hose. (1) Pinch the retainer and then raise it. NOTICE: * Do not use any tools in this procedure. * Check for any dirt and foreign matter contamination in the valve and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the valve and connector. Floor Speaker (for CrewMax) Speaker: Testing and Inspection Floor Speaker (for CrewMax) AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSPECTION 1. INSPECT NO. 1 BOX SPEAKER ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the speaker assembly. Page 6750 J/B No.3 Inner Circuit J/B No.4 Inner Circuit J/B No.5 Inner Circuit Page 5284 (a) Install the insulator bracket with the 2 bolts. Torque : 30 Nm (306 kgf-cm, 22 ft-lbf) Components PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: COMPONENTS Page 3092 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 3239 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 1806 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 650 Page 9002 Page 8683 Garage Door Opener Transmitter: Programming and Relearning GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: REGISTRATION 1. REGISTER TRANSMITTER CODE HINT * The vehicle's garage door opener records transmitter codes for systems such as garage doors, gates, entry gates, door locks, home lighting systems, security systems or other transmitter code based systems. * The garage door opener is built into the inner rear view mirror. If replacing the inner rear view mirror, transmitter codes for any systems previously registered in the garage door opener must be reregistered. (a) Reregister systems in the garage door opener registration mode. CAUTION: Do not perform transmitter code registration for a system if people or objects are near the system. When registering transmitter codes for a system, injury or damage can occur because the system may open, close, unlock or otherwise operate. NOTICE: * Before transmitter code registration, confirm that all the electrical systems (headlight, blower motor, rear defogger, etc.) are turned off and no key is in the vehicle. * The garage door opener cannot be used with systems that: 1) were manufactured before April 1, 1982; or 2) do not meet Federal Standards (for example, garage doors without a jam protection function). HINT * 3 transmitter codes can be registered with the garage door opener, one transmitter code for each of the 3 garage door opener switches. * Disconnecting the battery will not erase the transmitter codes registered with the garage door opener. * An attempt to overwrite a previously registered transmitter code with a new system's transmitter code may fail. In this situation, the previously registered transmitter code will not be erased. (1) Select a garage door opener switch for transmitter code registration. (2) Press and hold the selected switch for 20 seconds. The garage door opener will enter registration mode. HINT Before entering registration mode, the LED illuminates. After entering registration mode, the LED flashes at a cycle of 1 Hz. For a "rolling code" type system, after entering registration mode, the LED flashes at a cycle of 8.8 Hz for 1.6 seconds, and then the LED flashes at a cycle of 1 Hz. (3) After the garage door opener has entered registration mode, bring the original transmitter of the system to be registered within 1 to 3 inches of the garage door opener and press and hold one of the garage door opener switches. Then press the original transmitter switch. (4) If the transmitter code registration was successful, the LED of the garage door opener flashes at a cycle of 5.6 Hz. If no malfunction occurs, release both the garage door opener switch and the original transmitter switch. HINT * If transmitter code registration fails: 1) the original transmitter's battery may be low or need to be replaced, or 2) the system you are trying to register may not be compatible with the garage door opener. Locations Gear Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 8736 ^ This condition is NOT reception related. Switching modes will not correct the condition. ^ This condition affects XM ONLY - AM/FM reception is normal when this condition occurs. If cycling the ignition key does NOT restore normal operation, this TSB does NOT apply. Warranty Information APPLICABLE WARRANTY ^ Toyota-supplied satellite radio component systems installed as original equipment are warranted for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Toyota-supplied satellite radio components installed by a Toyota dealer are warranted for 12 months, regardless of mileage from the date of installation on the vehicle, or the remainder of the applicable New Vehicle Limited Warranty for 36 months or 36,000 miles, whichever provides the greater coverage. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Order parts through the Pioneer exchange program. Service Exchange Part Identification Countermeasure parts have a "P" marking on the parts label following the Toyota part number (see Figure 1). Required Tools & Equipment NOTE Page 3608 A/F and 02 Sensor Identification Page 2164 Tire Pressure Warning Reset Switch: Diagrams Page 2398 (f) Remove the oil filter element and O-ring from the oil filter cap. NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent damage to the cap's O-ring groove. 4. INSTALL OIL FILTER ELEMENT (a) Clean the inside of the oil filter cap, its threads and its O-ring groove. (b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap. (c) Set a new oil filter element to the oil filter cap. (d) Remove any dirt or foreign matter from the installation surface of the engine. (e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap. (f) Using SST, tighten the oil filter cap. SST : 09228-06501 Torque : 25 Nm (255 kgf-cm, 18 ft-lbf) NOTICE: * When tightening the oil filter cap, do not remove the oil filter bracket clip. * Make sure that the oil filter is installed securely as shown in the illustration. * Be careful that the O-ring does not get caught between any surrounding parts. Page 427 Fuel Pump Control Unit: Service and Repair Removal 1UR-FE FUEL: FUEL PUMP ECU: REMOVAL 1. REMOVE FUEL PUMP ECU (a) Disconnect the 2 fuel pump ECU connectors. (b) Remove the 2 bolts and fuel pump ECU. NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being dropped, etc. Page 2338 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Specifications Wheel Fastener: Specifications FRONT WHEEL For Aluminum Wheel Torque.................................................................................................................................................. .................................131 Nm (1336 kgf-cm, 97 ft-lbf) For Steel Wheel Torque.................................................................................................................................................. ...............................209 Nm (2131 kgf-cm, 154 ft-lbf) REAR WHEEL For Aluminum Wheel Torque.................................................................................................................................................. .................................131 Nm (1336 kgf-cm, 97 ft-lbf) For Steel Wheel Torque.................................................................................................................................................. ...............................209 Nm (2131 kgf-cm, 154 ft-lbf) Page 9124 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 7986 (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold Down Seat Type): COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold Down Seat Type): REMOVAL Page 5895 Traction Control Switch: Testing and Inspection BRAKE CONTROL: VSC OFF SWITCH: INSPECTION 1. INSPECT VSC OFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the VSC OFF switch. Page 6537 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 7997 (b) Pull out the steering pad from the steering wheel, as shown in the illustration. Then support the steering pad with one hand. NOTICE: When removing the steering pad, do not pull the airbag wire harness. (c) Disconnect the 2 connectors and remove the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 5. REMOVE STEERING PAD (w/o Steering Pad Switch) (a) Using a T30 "TORX" socket wrench, loosen the 2 screws until the groove along the screw circumference catches on the screw case. (b) Pull out the steering pad from the steering wheel, as shown in the illustration. Then support the steering pad with one hand. NOTICE: Page 5219 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Locations Neutral Safety Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 6186 5. INSTALL POWER OUTLET SOCKET ASSEMBLY (a) Attach the claw to install the power outlet socket. 6. INSTALL CONSOLE BOX BEZEL (a) Attach the 5 claws to install the console box bezel. (b) Connect the connector. 7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation Page 3543 INSPECTION PROCEDURE PROCEDURE 1. CHECK HARNESS AND CONNECTOR (ECM - BATTERY AND BODY GROUND) (a) Disconnect the A24 and D74 ECM connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) Measure the voltage according to the value(s) in the table below. Standard voltage: Front Seat Heater Switch Seat Heater Switch: Diagrams Front Seat Heater Switch Page 6098 Starter Motor: Diagrams Starter Page 1224 Power Steering Pressure Switch: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: REMOVAL 1. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DRAIN POWER STEERING FLUID 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the power steering oil pressure switch connector. (b) Remove the power steering oil pressure switch. (c) Remove the O-ring. Page 6706 Fuse Block: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Multiplex Communication Information Bus: Tools and Equipment Multiplex Communication PREPARATION: MULTIPLEX COMMUNICATION: RECOMMENDED TOOLS Components Wiring Harness: Service and Repair Components A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS Page 1800 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Initial Inspection and Diagnostic Overview Neutral Safety Switch: Initial Inspection and Diagnostic Overview A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ON-VEHICLE INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Apply the parking brake and turn the ignition switch to ON. (b) Depress the brake pedal and check that the engine starts when the shift lever is in N or P, but does not start when the shift lever is in other positions. (c) Check that the back-up light illuminates and the reverse warning buzzer sounds when the shift lever is in R, but do not function when the shift lever is in other positions. Page 6869 Power Distribution Relay: Diagrams Page 1198 Engine Bank Identification Page 7895 Solar Sensor: Testing and Inspection AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSPECTION 1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Connect the battery's positive (+) lead to terminal 6 and the negative (-) lead to terminal 3, then measure the voltage according to the value(s) in the table below. Standard voltage: NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. HINT * As the inspection light is moved away from the sensor, the voltage decreases. * Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. (b) If the result is not as specified, replace the solar sensor. Front Door Courtesy Switch Door Switch: Testing and Inspection Front Door Courtesy Switch LIGHTING: FRONT DOOR COURTESY SWITCH: INSPECTION 1. INSPECT FRONT DOOR COURTESY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 4715 Standard resistance: (4) If the resistance is not as specified, repair or replace the harness or connector. (c) Check the 4WD control switch. (1) Turn the ignition switch OFF. (2) Connect the L1 switch connector. (3) Connect the A25 and A26 ECU connectors. (4) Measure the voltage according to the value(s) in the table below. Standard voltage: (5) If the voltage is not as specified, check the 4WD control ECU. (d) Check the 4WD control ECU. (1) Disconnect the L1 switch connector. (2) Measure the voltage according to the value(s) in the table below. Page 6865 Power Distribution Module: Service and Repair Installation OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION 1. INSTALL VOLTAGE INVERTER ASSEMBLY (a) Connect the voltage inverter connector. (b) Install the voltage inverter with the 2 bolts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Diagrams Seat Memory Switch: Diagrams Page 5959 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 6170 Auxiliary Power Outlet: Connector Views Power Outlet Socket Page 7693 (d) Connect the discharge hose on the cooler condenser with the bolt. Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) NOTICE: * When tightening the bolt, do not allow any tools to contact the pipe. * When tightening the bolt, hold a part of the pipe near the connector. 5. INSTALL RADIATOR ASSEMBLY (a) for 1GR-FE: Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Installation. (b) for 1UR-FE: Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Installation. (c) for 3UR-FE: Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Installation. (d) for 3UR-FBE: Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Installation. 6. CONNECT OIL COOLER HOSE (w/ Air Cooled Transmission Oil Cooler) (a) Connect the 2 oil cooler hoses and attach the 2 clips. 7. INSTALL FRONT BUMPER COVER (a) for Steel Type Bumper: Install the front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation. (b) for Resin Type Bumper: Install the front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation. 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHARGE REFRIGERANT See: Service and Repair 10. WARM UP ENGINE See: Service and Repair 11. CHECK FOR REFRIGERANT GAS LEAK See: Service and Repair 12. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Check Mode Procedure. Page 6776 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 6264 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 7640 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 6592 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 842 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE REAR WHEEL 3. REMOVE REAR SPEED SENSOR LH (a) Disconnect the speed sensor connector (labeled A). (b) Remove the nut (labeled B) and speed sensor (labeled C). 4. REMOVE REAR SPEED SENSOR RH (a) Disconnect the speed sensor connector (labeled A). (b) Remove the nut (labeled B) and speed sensor (labeled C). 5. REMOVE SKID CONTROL SENSOR WIRE (a) Disconnect the sensor connector (labeled A). (b) Detach the 7 clips (labeled B). (c) Remove the bolt (labeled C). (d) Remove the nut (labeled D) and skid control sensor wire. Installation BRAKE CONTROL: REAR SPEED SENSOR: INSTALLATION Page 6803 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 7314 1. REMOVE FRONT WHEEL 2. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING LH (a) Remove the front shock absorber with coil spring See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Removal. 3. DISCONNECT SKID CONTROL SENSOR WIRE (a) Remove the 2 bolts and disconnect the sensor wire from the steering knuckle and suspension upper arm. 4. DISCONNECT STEERING KNUCKLE LH (a) Support the front suspension lower arm LH with a jack. (b) Remove the clip and the nut. (c) Using SST, disconnect the upper ball joint from the steering knuckle. SST : 09628-62011 5. REMOVE FRONT FENDER APRON SEAL LH (a) Using a clip remover, remove the 6 clips and apron seal. 6. REMOVE FRONT FENDER APRON SEAL REAR LH Page 5352 Transmission Speed Sensor: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL 1. REMOVE SPEED SENSOR NT (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. 2. REMOVE SPEED SENSOR SP2 (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. (c) Remove the O-ring from the sensor. Front Lower Suspension Arm Ball Joint: Testing and Inspection Front Lower Suspension Arm SUSPENSION: FRONT LOWER SUSPENSION ARM: INSPECTION 1. INSPECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH (a) As shown in the illustration, move the ball joint stud back and forth 5 times before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the fifth turn. Standard turning torque: 3.0 to 10.0 N*m (31 to 102 kgf*cm, 27 to 89 in.*lbf) (c) Check for any cracks and grease leaks on the ball joint dust cover. Page 316 Body Control Module: Locations LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 2482 (b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. HINT Be sure to arrange the removed parts for each installation position separately. NOTICE: * Be careful not to drop washers into the cylinder head. * Head warpage or cracking could result from removing bolts in an incorrect order. 7. REMOVE CYLINDER HEAD GASKET RH Installation 1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 2): INSTALLATION 1. INSPECT CYLINDER HEAD SET BOLT See: Testing and Inspection/Engine Unit 2. INSPECT CYLINDER HEAD SUB-ASSEMBLY RH See: Cylinder Head Assembly/Testing and Inspection 3. INSTALL CYLINDER HEAD GASKET RH (a) Check the piston protrusions for each cylinder. (1) Clean the cylinder block with solvent. (2) Set the piston of the cylinder to be measured to slightly ATDC. (b) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward. NOTICE: * Be careful of the installation direction. * Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket. 4. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH (a) Place the cylinder head on the cylinder block. NOTICE: Page 4191 Page 7004 Driver Side J/B Inner Circuit Page 6611 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 4405 (a) Remove the fuel suction with pump and gauge tube See: Fuel Pump/Service and Repair/Removal and Replacement/Removal. 2. REMOVE FUEL SENDER GAUGE ASSEMBLY (a) Disconnect the fuel sender gauge connector. (b) Press down on the sender gauge claw labeled A. Then slide the sender gauge upward to remove it. Installation 1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSTALLATION 1. INSTALL FUEL SENDER GAUGE ASSEMBLY (a) Set the sender gauge to the fuel sub tank. Then slide the sender gauge downward to install it. (b) Connect the fuel sender gauge connector. 2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (a) Install the fuel suction with pump and gauge tube See: Fuel Pump/Service and Repair/Removal and Replacement/Installation. Page 6329 Multiple Junction Connector: Locations Wire and Wire In Seat [Separate Seat] PZ1-ZU1 PZ1-ZU1 Page 6268 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 355 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 4283 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 7699 Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. 4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Regular Cab) 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Double cab, CrewMax) 6. REMOVE FRONT PILLAR GARNISH LH 7. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 8. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 10. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 11. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 12. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 13. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 14. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 15. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (a) Detach the 4 clips. Page 7976 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ROOF HEADLINING ASSEMBLY HINT * Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (for Double Cab) See: Body and Frame/Interior Page 3809 Engine Temperature Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the sensor. (b) Using a 19 mm ball joint lock nut wrench, install the sensor. Torque : 20 Nm (200 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench See: Service Precautions (c) Connect the sensor connector. 2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 1357 Air Bag Deactivation Switch: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 9052 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. Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 3897 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 1641 Power Window Switch: Testing and Inspection Rear Power Window Switch WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: INSPECTION 1. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: * If the result is not as specified, replace the regulator switch. Page 8322 5. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System Page 8126 Seat Occupant Classification Module - Air Bag: Diagrams Page 2034 J/B No.4 - Instrument Panel Center Page 606 4. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 5. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 6. REMOVE REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 7. REMOVE REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 8. REMOVE REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 9. REMOVE REAR BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 10. REMOVE REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 11. REMOVE NO. 1 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the rear bumper. 13. REMOVE NO. 2 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. Page 6139 Page 635 (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY Page 3828 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: INSTALLATION 1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Install a new O-ring to the manifold absolute pressure sensor. (b) Install the manifold absolute pressure sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) (c) Connect the manifold absolute pressure sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 9383 3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount. These will be reused when installing the new No.3 cab mount bolts. 4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse. 5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount bolts. Page 1495 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 5189 Removal AXLE: REAR AXLE SHAFT: REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE REAR WHEEL LH 3. DRAIN BRAKE FLUID See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Flexible Hose/Removal Locations Steering Column Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 7509 Tire Pressure Warning Reset Switch: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING RESET SWITCH (a) Attach the 2 claws to install the reset switch. (b) Connect the switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 1681 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 7925 (b) With the lower No. 1 instrument panel airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the lower No. 1 instrument panel airbag with a new one: * Cuts, minute cracks or marked discoloration on the lower No. 1 instrument panel airbag. * Cracks or other damage to the connector. * Deformation or cracks on the instrument panel reinforcement. CAUTION: For removal and installation procedures of the lower No. 1 instrument panel airbag, be sure to follow the correct procedure. Front Passenger Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY: ON-VEHICLE INSPECTION 1. CHECK FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front passenger airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the instrument panel with a new one: Cuts, minute cracks or marked discoloration on the instrument panel around the front passenger airbag. 2. CHECK FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 9013 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 4136 Page 8987 (a) Connect the connector. (b) Attach the 4 clips to install the panel. 3. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 6. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 9. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 1009 Parking Brake Warning Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Driver Side Squib Circuit Air Bag: Diagrams Driver Side Squib Circuit Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Page 5578 Brake Fluid Pump Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 1330 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 8783 (b) If the result is not as specified, replace the speaker assembly. Front Door Courtesy Switch Door Switch: Diagrams Front Door Courtesy Switch Front Shock Absorber Suspension Strut / Shock Absorber: Testing and Inspection Front Shock Absorber SUSPENSION: FRONT SHOCK ABSORBER: INSPECTION 1. INSPECT FRONT SHOCK ABSORBER ASSEMBLY LH (a) Compress and extend the shock absorber rod 4 times or more. Check that there is no abnormal resistance or unusual sound during the operation. * If there is any abnormality, replace the shock absorber assembly with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL See: Service and Repair/Removal and Replacement/Front Shock Absorber/Disposal Page 389 Page 2943 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Page 2748 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 9239 Disassembly ENGINE HOOD / DOOR: REAR DOOR (for CrewMax): DISASSEMBLY REAR DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH (a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel. Emissions - MIL ON/Multiple Air Injection DTC's Set Air Diverter Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 7480 Tire Pressure Module: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the ECU with the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the ECU connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 7. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Testing and Inspection/Programming and Relearning/Registration. 8. PERFORM INITIALIZATION (a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 9. CHECK TIRE PRESSURE AFTER REPAIRS Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 2036 J/B No.6 Assembly - Instrument Panel Center Page 7073 Steering Column Control Module: Diagrams Page 7205 Steering Control Module: Service and Repair Removal POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE POWER STEERING ECU ASSEMBLY (a) Disconnect the power steering ECU connector. (b) Remove the nut and power steering ECU. Page 710 (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 4014 HINT Make sure the direction of the hose clamp is as shown in the illustration. (b) Connect the connector. Page 9015 Push the terminal retainer down to the temporary lock position. Page 3188 Body Control Module: Locations LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 2558 Variable Valve Timing Actuator: Diagrams Page 3384 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Engine Control System - SFI System Camshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Components Four Wheel Drive Selector Switch: Service and Repair Components JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS Components Alarm System Transmitter: Service and Repair Components ENGINE IMMOBILISER: TRANSPONDER KEY ECU: COMPONENTS Page 2381 Drive Belt: Service and Repair Removal 1UR-FE ENGINE MECHANICAL: DRIVE BELT: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and Repair/Replacement 3. REMOVE FAN AND GENERATOR V BELT (a) While turning the belt tensioner counterclockwise, align the service hole for the belt tensioner and the belt tensioner fixing position, and then insert a bar of dia 5 mm (0.197 in.) into the service hole to fix the belt tensioner in place. HINT The pulley bolt for the belt tensioner has a left-hand thread. (b) Remove the V belt. Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Oil Change Reset Procedure 1. Turn the engine switch off with the trip meter A reading shown. 2. While pressing the trip meter reset button, turn the engine switch on. Without multi-information display 3. Continue to press and hold the button until the trip meter displays 000000. With multi-information display 3. Continue to press and hold the button until "MAINT REQD RESET MODE COMPLETE" appears in the display. Navigation Maintenance Item Setting (If equipped) When the navigation system is turned on, the "Information" screen displays when it is time to replace a part or certain components. 1. Push the "INFO" button. 2. Touch "Maintenance" 3. Touch the desired button. "Delete All": To cancel all conditions which have been input. "Reset All" : To reset the item which has satisfied a condition. If "ON" is selected, the system gives maintenance information with the "Information" screen when the system is turned on. If "OFF" is selected, the "Information" screen is disabled. When the vehicle needs to be serviced, the touch screen button color will change to orange. 4. Input the conditions. Notice of "Date": The next maintenance date can be input. Notice of "Distance": The driving distance until the next maintenance check can be input. "Delete": To cancel the date and distance conditions. "Reset": To reset the date and distance conditions. 5. Touch "OK" The screen returns to the "Maintenance" screen. Note: - For scheduled maintenance information, please refer to the Scheduled maintenance guide or Owners manual supplement. - Depending on your driving or the road conditions, the system may have a time-lag between the data which has been input and the actual date and driving distance. Page 5075 SST : 09316-60011 09316-00041 34. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 35. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a hammer, tap in a new oil seal. SST : 09502-12010 SST : 09316-60011 09316-00041 Standard oil seal depth: 5.6 to 6.6 mm (0.221 to 0.260 in.) (b) Coat the lip of the oil seal with MP grease. 36. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT (a) Using SST, install the companion flange. SST : 09950-30012 09951-03010 09953-03010 09954-03010 09955-03030 Page 3984 Required Tools & Equipment Repair Procedure 1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446 and/or P2447 are present. 2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal from the air injection control driver is reaching the air pumps. ^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2 of the pumps during this test. ^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis. Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual: 3. If during the test voltage is present at the pump and the pump is NOT running or the Air Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump running remove the air pump assemblies for inspection. Refer to TIS 2010 model year Tundra Repair Manual: 4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered the pumps. ^ YES - If there is liquid evidence go to step 5. ^ NO - If there is NO evidence of liquid go to step 7. 5. If liquid is present replace the affected pump assembly. Refer to TIS 2010 model year Tundra Repair Manual: Page 3205 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 6725 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 6962 Page 4838 * When you have replaced the transmission hose and/or output shaft oil seal, proceed to the "Fluid Temperature Check" procedures. 3. TRANSMISSION FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. (c) Reinstall the overflow plug. (d) Fill the transmission with the amount of fluid listed in the table below. Reference Capacity: (e) Install the refill plug. HINT If you cannot fill the listed amount of fluid, perform the following: (1) Start the engine and idle it. NOTICE: Check that electrical systems such as the air conditioning system, audio system and lighting system are off. (2) Move the shift lever through the entire gear range to circulate the fluid. (3) Wait for 30 seconds with the engine idling. (4) Stop the engine. (5) Remove the refill plug. (6) Fill the transmission with the remaining fluid until the amount in the table has been filled. (7) Install the refill plug. 4. FLUID TEMPERATURE CHECK Page 9203 Page 7796 Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 6337 Multiple Junction Connector: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 1211 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. (c) for 2WD: Connect the air fuel ratio sensor connector. 2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Connect the front No. 2 exhaust pipe to the exhaust pipe support. (b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts. Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (c) Connect the air fuel ratio sensor connector. (d) Connect the heated oxygen sensor connector. 3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) Page 3612 Oxygen Sensor: Diagrams Heated Oxygen Sensor Page 9339 Tires - Pressure Compensation And Adjustment Tires: Technical Service Bulletins Tires - Pressure Compensation And Adjustment T-SB-0345-08 Rev2 November 6, 2008 Tire Inflation Pressure Compensation and Adjustment Service Category Suspension Section Tire/Wheel Market USA Applicability TSB REVISION NOTICE ^ December 22, 2009 Rev2: ^ Applicability has been updated to include 2010 model year Prius PHV model and 2011 vehicles. Any previous printed versions of this service bulletin should be discarded. TSB REVISION NOTICE ^ May 15, 2009 Rev1: ^ Applicability has been updated to include 2010 model year vehicles, and 2009 - 2010 model year Venza. ^ Figure 1 has been updated, and Celsius temperatures have been removed from the bulletin. Any previous printed versions of this service bulletin should be discarded. Page 3658 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 6420 Power Distribution Module: Service and Repair Removal OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 6. REMOVE VOLTAGE INVERTER ASSEMBLY (a) Remove the 2 bolts. (b) Disconnect the voltage inverter connector and removal the voltage inverter. Page 5199 (f) Install the 6 balls. HINT Apply grease onto the balls to keep them from falling out. (g) Pack the inboard joint shaft and boot with grease in the boot kit. Standard grease capacity: 380 to 400 g (13.3 to 14.1 oz.) (h) Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard joint shaft. (i) Install a new snap ring. (j) Temporarily install the boot to the inboard joint shaft. HINT Make sure that the boot is on the shaft groove. (k) Check that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Standard drive shaft length (A): 625.8 mm (2.05 ft.) Page 5030 Replacement/Front Propeller Shaft Assembly/Removal. 5. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Remove the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Removal and Replacement/Front Drive Shaft Assembly/Removal. 6. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH HINT Use the same procedure as the LH side. 7. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Remove the bolt and disconnect the front differential breather tube bracket. (b) Disconnect the automatic disconnecting differential actuator hose. (c) Disconnect the automatic disconnecting differential actuator connector. (d) Support the front differential with a jack. (e) Remove the A, B, C, D and E bolts. (f) Slowly lower the jack, and remove the front differential carrier. (g) Remove the F and G bolts, and differential support. Installation DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): INSTALLATION 1. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Install the differential support with the F and G bolts. Torque : 100 Nm (1019 kgf-cm, 74 ft-lbf) (b) Using a jack, slowly raise the front differential carrier assembly to its installation position. (c) Temporarily install the A, B, C, D and E bolts. (d) Tighten the A bolt. Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf) (e) Tighten the B and C bolts. Page 7043 Standard vehicle height (unloaded vehicle): for Double Cab of Long Deck Standard vehicle height (unloaded vehicle): for CrewMax of standard deck Page 7042 Standard vehicle height (unloaded vehicle): for Regular Cab of Long Deck Standard vehicle height (unloaded vehicle): for Double Cab of Standard Deck Page 8541 Cellular Phone Microphone: Service and Repair Removal AUDIO / VISUAL: MICROPHONE AMPLIFIER: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE ROOF CONSOLE BOX ASSEMBLY (a) Remove the roof console box See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. 3. REMOVE MICROPHONE AMPLIFIER ASSEMBLY (a) Disconnect the connector. (b) Detach the 2 claws and clip, and remove the microphone. Page 1241 Variable Valve Timing Actuator Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION 1. INSTALL VVT SENSOR (a) Install the 4 sensors with the 4 bolts. Page 5044 SST : 09330-00021 09330-00030 (d) Coat the threads of the nut with hypoid gear oil. (e) Install the nut by tightening it until the standard preload is reached. Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less) NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. (f) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Standard preload (at starting): HINT Measure the total preload after first turning the bearing clockwise and counterclockwise several times to make the bearing smooth. 11. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY (a) Place the 2 bearing outer races on their respective bearings. NOTICE: Do not interchange the right and left race. 12. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT (a) Install the 2 adjusting nuts onto the carrier, making sure the nuts are threaded properly. Page 218 Horn Relay: Testing and Inspection HORN: INTEGRATION RELAY: ON-VEHICLE INSPECTION 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: * Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning * After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. 2. REMOVE INTEGRATION RELAY (UNIT E) (a) Remove the engine room relay block cover. (b) Using a screwdriver, detach the 2 claws and disconnect the integration relay from the engine room relay block. HINT Tape the screwdriver tip before use. (c) Disconnect the 3 connectors. 3. INSPECT INTEGRATION RELAY (HORN RELAY) NOTICE: * Some relays are built into the integration relay (unit E). The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the HORN fuse. Page 8932 Integrated Accessory Switch Assembly: Service and Repair Removal METER: DRIVE MONITOR SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE DRIVE MONITOR SWITCH (a) Detach the 2 claws and remove the monitor switch. Page 6996 Driver Side J/B - Cowl Side Left Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6922 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 6527 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 5779 (c) Connect the parking brake switch connector. 2. CONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Connect the parking brake cable to the control pedal. (b) Using needle-nose pliers, slowly bend down the claw. NOTICE: Be careful not to damage the parking brake cable or claw. (c) Install the clip to the control pedal. (d) Temporarily install the adjustment nut and lock nut. HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE PEDAL TRAVEL" procedure. 3. CHECK PARKING BRAKE PEDAL TRAVEL See: Adjustments 4. ADJUST PARKING BRAKE PEDAL TRAVEL See: Adjustments 5. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 745 Seat Memory Switch: Testing and Inspection SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSPECTION 1. INSPECT SEAT MEMORY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 5190 4. DISCONNECT REAR BRAKE FLEXIBLE HOSE (a) Disconnect the brake tube from the flexible hose with union nut wrench while holding the flexible hose with a wrench. NOTICE: * Do not bend or damage the brake tube. * Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting point. (b) Remove the clip. 5. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH (a) Remove the 2 bolts and disconnect rear disc brake cylinder. NOTICE: * Do not twist or bend the flexible hose. * Do not disconnect the flexible hose from the disc brake cylinder. 6. REMOVE REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Removal 7. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 8. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 9. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 10. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 11. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY See: Brakes and Traction Control/Parking Brake System/Service and Repair/Disassembly 12. DISCONNECT REAR SPEED SENSOR LH See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Speed Sensor/Removal 13. REMOVE REAR AXLE SHAFT (a) Remove the 4 nuts and rear axle shaft together with the parking brake plate. Center Airbag Sensor Assembly (for Column Shift Type) Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 5047 Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf) 15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (a) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue. (b) Turn the companion flange in both directions to inspect the ring gear for proper tooth contact. * If the teeth are not contacting properly, use the following table to select a proper washer for correction. Washer thickness: Page 5646 Page 8125 Seat Occupant Classification Module - Air Bag: Locations Seat Belt Warning System SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION Page 7335 6. INSTALL FRONT AXLE HUB SUB-ASSEMBLY LH (a) Install the front axle hub See: Wheel Hub/Service and Repair/Removal and Replacement/Installation. 7. CONNECT FRONT SPEED SENSOR LH (a) Connect the front speed sensor to the steering knuckle with the bolt. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Attach the clip to the steering knuckle. 8. INSTALL FRONT WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 12. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair. Page 8528 (a) Connect the connector. (b) Attach the 4 clips to install the panel. 3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 4993 (c) Install the valve body with the 19 bolts. Torque : 11 Nm (112 kgf-cm, 8 ft-lbf) HINT Each bolt length is indicated below. 36 mm (1.42 in.) for bolt A 25 mm (0.984 in.) for bolt B 45 mm (1.77 in.) for bolt C 50 mm (1.97 in.) for bolt D (d) Install the detent spring and detent spring cover with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 2. CONNECT TRANSMISSION WIRE See: Wiring Harness/Service and Repair/Installation 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY See: Wiring Harness/Service and Repair/Installation 4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY See: Wiring Harness/Service and Repair/Installation 5. ADD AUTOMATIC TRANSMISSION FLUID (a) Add automatic transmission fluid See: Service and Repair/Procedures. Locations Tire Pressure Warning Reset Switch: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 4414 Main Relay (Computer/Fuel System): Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION 1. REMOVE CIRCUIT OPENING RELAY (C/OPN) (a) Remove the circuit opening relay from the engine room relay block. 2. INSPECT CIRCUIT OPENING RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the circuit opening relay. 3. INSTALL CIRCUIT OPENING RELAY (a) Install the circuit opening relay to the engine room relay block. Page 8937 Page 2914 Camshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 6144 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 1604 Standard voltage: (3) If the voltage is not as specified, replace the 4WD control ECU See: Powertrain Management/Transmission Control Systems/Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. If the voltage is normal, replace the 4WD control switch. Page 6605 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 6314 Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Column Shift] AJ1-QK1 Door Control Receiver (for CrewMax) Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax) Components DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS Removal DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal Page 9074 Page 9008 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 6757 Da1-RA3 Page 6810 Page 945 15. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY (a) Attach the 4 claws to install the duct. 16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY (a) Attach the 4 claws to install the nozzle. 17. INSTALL AIR CONDITIONING UNIT (a) Install the air conditioning unit See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Installation. Page 9204 Disassembly ENGINE HOOD / DOOR: FRONT DOOR (for CrewMax): DISASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. Page 6730 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 9250 Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Page 690 (6) If the result is not as specified, replace the outer mirror switch. (b) Inspect the retract switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: (2) If the result is not as specified, replace the outer mirror switch. Airbag Cut-OFF Switch Air Bag Deactivation Switch: Service and Repair Airbag Cut-OFF Switch Components SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Remove the lower No. 2 instrument panel airbag assembly See: Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal. 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE AIRBAG CUT-OFF SWITCH (a) Detach the 2 claws to remove the switch. Installation SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSTALLATION 1. INSTALL AIRBAG CUT-OFF SWITCH (a) Attach the 2 claws to install the switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Install the lower No. 2 instrument panel airbag assembly See: Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 5666 Yaw Rate Sensor: Diagrams Page 9099 Symbols Used Within Diagrams Symbols Used Within Diagrams Locations Relay Box: Locations Engine Compartment Engine - Snow Ingestion Into Air Cleaner Box Front Fender Liner: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information CAN Communication System Body Control Module: Locations CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION Page 7350 8. REMOVE REAR SPRING ASSEMBLY LH (a) Remove the nut, washer and bolt from the front side. (b) Remove the 2 nuts, 2 washers, shackle outer plate, No. 2 spring shackle plate and leaf spring from the rear side. 9. REMOVE TUBE (a) Using a brass bar and hammer, remove the tube from the frame. 10. REMOVE REAR SPRING SHACKLE BUSH (a) Remove the 2 bushes from the frame. Installation SUSPENSION: REAR LEAF SPRING: INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL REAR SPRING SHACKLE BUSH (a) Install the 2 shackle bushes to the frame. Page 4610 Ignition Switch: Testing and Inspection 1UR-FE STARTING: IGNITION SWITCH: INSPECTION 1. INSPECT IGNITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the ignition switch assembly. Page 1404 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 6735 Engine Room R/B, J/B - Engine Compartment Left Ultrasonic Sensor (for Front Side) Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Front Side) Components PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): COMPONENTS Components Front Steering Knuckle: Service and Repair Components AXLE: STEERING KNUCKLE: COMPONENTS Page 3458 (c) Measure the voltage according to the value(s) in the table below. Standard voltage: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE CENTER AIRBAG SENSOR Combination Meter ECU Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Combination Meter ECU Communication Stop Mode - Combination Meter ECU Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. CHECK HARNESS AND CONNECTOR (COMBINATION METER ECU - BATTERY AND BODY GROUND) Page 5507 Control Module: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION 1. INSTALL 4WD CONTROL ECU (a) Install the ECU with the bolt. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. Page 4784 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 1983 Page 1197 Page 8106 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Components Transmission Speed Sensor: Service and Repair Components A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS Page 5045 13. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH (a) Align the matchmarks on the bearing cap and carrier. (b) Install the right and left bearing caps with the 4 bolts. Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf) * If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary. (c) Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned using SST. SST : 09504-00011 (d) Using SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.00788 in.). (e) While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity (drain and refill-Reference) With filter .............................................................................................................................................. ............................................................. 7.9 qt (7.5L) Without filter ...................................................... ................................................................................................................................................ 7.4 qt (7.1L) Page 8837 NOTICE: Do not touch the cone part of the speaker. 7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY RH (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. NOTICE: Do not touch the cone part of the speaker. 8. REMOVE NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Using a screwdriver, detach the 6 clips and 2 claws. HINT Tape the screwdriver tip before use. (b) Remove the speaker panel. 9. REMOVE FRONT NO. 4 SPEAKER ASSEMBLY (for 10 Speakers) (a) Remove the 2 bolts. (b) Remove the speaker and disconnect the connector. Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 1483 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 6084 Neutral Safety Switch: Component Tests and General Diagnostics A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the switch assembly. Page 4475 Throttle Body: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: INSPECTION 1. INSPECT THROTTLE BODY ASSEMBLY (a) Check the throttle valve. (1) Check that the throttle valve opens and closes smoothly. (2) Check that there is no sludge accumulating around the throttle body. (b) Check the throttle control motor. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the throttle body assembly. Page 3373 Push the terminal retainer down to the temporary lock position. Page 8576 Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Rear Side) Components PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): COMPONENTS Page 1393 Impact Sensor: Service and Repair Side Airbag Sensor (for CrewMax) Components SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): COMPONENTS Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 4905 3. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 4. INSTALL UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 5. INSTALL LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 7. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 8. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 9. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 11. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 12. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 13. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 15. INSPECT SHIFT LEVER POSITION See: Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type) Components A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): COMPONENTS Page 6583 Page 3623 (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf) with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the wrench are connected in a straight line. 2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. A760F Automatic Transmission System Control Module: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 4757 ^ 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 61 Parking Assist Control Module: Service and Repair Installation PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: INSTALLATION HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL CLEARANCE WARNING ECU ASSEMBLY (a) Install the clearance warning ECU to the bracket with the 2 nuts. NOTICE: * Avoid any impact to the clearance warning ECU. * Do not drop the ECU. If it is dropped, replace it with a new one. 2. INSTALL CLEARANCE WARNING ECU WITH BRACKET (a) Install the ECU with bracket with the nut and bolt. (b) Connect the ECU connectors and attach the harness clamp. NOTICE: Do not apply excessive force to the wire harnesses. 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation 5. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation. Page 9237 Locations Four Wheel Drive Selector Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Locations Shift Solenoid: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 3539 DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. Page 8702 Seat Memory Switch: Service and Repair Removal SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): REMOVAL 1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 2. REMOVE FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE FRONT DOOR ARMREST COVER LH 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE SEAT MEMORY SWITCH (a) Remove the 2 screws and seat memory switch. Diagrams Steering Angle Sensor: Diagrams Page 9030 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 4954 (a) Disconnect the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet hose from the transmission oil thermostat. (b) Disconnect the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet hose from the oil cooler tube, and remove them. NOTICE: When disconnecting the hoses from the tube, support the tube by hand and be careful to prevent the tube from being deformed. (c) Disconnect the 2 No. 1 transmission oil cooler hoses from the transmission. (d) Remove the 3 bolts and transmission oil cooler with transmission oil thermostat. (e) Remove the 2 No. 1 transmission oil cooler hoses from the transmission oil thermostat. (f) Remove the 3 bolts and oil cooler from the transmission oil thermostat. (g) Remove the 2 O-rings from the grooves of transmission oil cooler. 6. REMOVE OIL COOLER ACCESSORY ASSEMBLY (w/ Trailer Towing System) (a) Disconnect the 2 hoses from the No. 2 oil cooler tube. NOTICE: When disconnecting the hoses from the tube, support the tube by hand and be careful to prevent the tube from being deformed. (b) Detach the claw to open the No. 1 flexible hose clamp. (c) Disconnect the 2 hoses from the oil cooler tube and remove the oil cooler accessory assembly. NOTICE: When disconnecting the hoses from the tube, support the tube by hand and be careful to prevent the tube from being deformed. 7. REMOVE COOLER CONDENSER ASSEMBLY (AIR COOLED OIL COOLER) (w/ Trailer Towing System) (a) Remove the cooler condenser See: Heating and Air Conditioning/Condenser HVAC/Service and Repair/Removal. 8. REMOVE NO. 2 OIL COOLER TUBE Page 6589 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 7840 Cabin Temperature Sensor / Switch: Diagrams Page 6421 Power Distribution Module: Service and Repair Installation OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION 1. INSTALL VOLTAGE INVERTER ASSEMBLY (a) Connect the voltage inverter connector. (b) Install the voltage inverter with the 2 bolts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 6070 Page 2343 Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the Techstream to the DLC3. (b) Start the engine and turn the tester ON. (c) Warm up the engine. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear (Bank 1) or Control the VVT Linear (Bank 2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2). (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK: (f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear. HINT * Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of bank 1 (Control range: Between -128 to 127%). * Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves of bank 2 (Control range: Between -128 to 127%). * Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range: ON/OFF). * Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range: ON/OFF). * Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of bank 1 (Control range: Between -128 to 127%). * Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of bank 2 (Control range: Between -128 to 127%). Page 951 Refrigerant Pressure Sensor / Switch: Diagrams Page 5618 Page 4306 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 7602 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 1909 Required Tools & Equipment Important Information ^ 100,000 Mile Maintenance Interval - Inspection only; ATF-WS does NOT require any flushing or changing during the life of the vehicle. ^ The use of Genuine Toyota ATF-WS is recommended. ^ The use of additives or aftermarket fluids that are considered compatible or substitutes may result in shift concerns and damage to the internal transmission components. ^ ATF-WS is NOT compatible with T-IV or Dexron ATF. ^ Containers storing Toyota ATF-WS should ALWAYS be sealed - If exposed to the atmosphere, ATF-WS may absorb moisture and potentially cause shift concerns if used in operation. ^ One time use only. ^ When performing repairs on ATF-WS equipped transaxles, it is important to use only new, clean ATF-WS when refilling the ATM. ^ ATF-WS equipped ATMs may use the overflow type procedure - Any fluid drained from the overflow plug should be discarded following proper local regulations and never reused. Failure to do so could result in shift concerns and damage to the internal transmission components. Page 8346 Impact Sensor: Service and Repair Front Airbag Sensor Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Locations Wiper Switch: Locations WIPER AND WASHER: WIPER AND WASHER SYSTEM: PARTS LOCATION Page 2787 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Components Solar Sensor: Service and Repair Components AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): COMPONENTS Component Tests and General Diagnostics Steering Angle Sensor: Component Tests and General Diagnostics BRAKE CONTROL: STEERING ANGLE SENSOR: INSPECTION 1. CHECK STEERING ANGLE SENSOR (a) Check the steering angle sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 6471 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 6854 Page 294 Engine Room R/B, J/B - Engine Compartment Left Diagrams Steering Angle Sensor: Diagrams Page 3645 Body Control Module: Locations LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 4789 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 679 (b) If replacing unlock warning switch assembly: (1) While pushing the pin, slide the switch to install the warning switch. (c) Connect the unlock warning switch connector. 2. INSTALL LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 3. INSTALL LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation Specifications Power Steering Fluid: Specifications Power Steering Fluid Type Type ......................................................................................................................................................... Automatic Transmission Fluid DEXRON II or III Page 4480 (f) Connect the 2 water by-pass hoses. HINT When connecting the hoses, make sure the paint marks and clips are as shown in the illustration. 2. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 3. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 4. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 5. INSTALL ENGINE UNDER COVER NO.1 See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 7. PERFORM INITIALIZATION NOTICE: * Be sure to perform this procedure after reassembling the throttle body assembly or removing and reinstalling any throttle body component. * Perform the following procedure after replacing the ECM, throttle body assembly or any throttle body components. The following procedure should also be performed if the throttle body is cleaned. * Be sure to perform this procedure after reconnecting the battery cable and replacing the ECM. (a) Disconnect the EFI NO. 1 fuse at the same time. Wait at least 60 seconds and reconnect the fuses. (b) Turn the ignition switch to the ON position without operating the accelerator pedal. NOTICE: If the accelerator pedal is operated, perform the above steps again. (c) Connect the Techstream to the DLC3 and clear the DTCs See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. (d) Start the engine and check that the MIL is not illuminated and that the idle speed is within the specified range when the A/C is switched off after the engine is warmed up. Standard: NOTICE: * Be sure to perform this step with all accessories off. * Make sure that the shift lever is in N or P. (e) Enter the following menus: Powertrain / Engine and ETC / Data List / All Data / Throttle Sensor Position. Sensor Output. Fully depress the accelerator pedal and check that the value is 60% or more. (f) Perform a road test and confirm that there are no abnormalities. Page 3555 Scan Tool Testing and Procedures MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT Using the Techstream to read the Data List allows values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Main Body / Data List. (e) According to the display on the Techstream, read the Data List. LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: TERMINALS OF ECU 1. CHECK MAIN BODY ECU (DRIVER SIDE JUNCTION BLOCK) Page 2803 ^ 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 6313 Da1-RA3 Page 5522 Transmission Position Switch/Sensor: Diagrams Page 5348 Transmission Speed Sensor: Diagrams Page 8947 HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the front bumper. Installation PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): INSTALLATION 1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER (a) Align the keyhole and protrusion as shown in the illustration. (b) Install the sensor retainer to the front bumper. NOTICE: Do not damage the bumper with the protrusion when installing the retainer. 2. INSTALL NO. 1 ULTRASONIC SENSOR (a) Attach the 2 claws to install the ultrasonic sensor. Page 1844 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 Components Seat Occupant Classification Module - Air Bag: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: COMPONENTS Page 4620 Diagrams Steering Mounted Controls Transmitter: Diagrams Power Door Lock Control System Power Door Lock Switch: Locations Power Door Lock Control System DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: PARTS LOCATION Up to 11/2009 Braking Sensor/Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 4421 Fuel Pump Control Unit: Locations Crew Max Body Page 3685 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 1203 Oxygen Sensor: Diagrams Heated Oxygen Sensor Page 5904 Wheel Speed Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 4188 Capacity Specifications Refrigerant Oil: Capacity Specifications COMPRESSOR OIL Standard (Oil capacity inside the new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) Page 6498 J/B No.5 - Instrument Panel Center Page 7514 Introduction The purpose of this bulletin is to provide a procedure to adjust tire pressure correctly when outside temperature is significantly colder or warmer than shop temperature. Seasonal temperature change can dramatically alter tire pressure, which can cause the tire pressure warning lamp to illuminate. NOTE This bulletin applies to some 2004 - 2007 model year Toyota vehicles with direct TPWS and all 2008 and newer model year Toyota vehicles. Warranty Information Tire Pressure vs. Tire Temperature Tire temperature is dependent on "cold" tire pressure, driving distance and speed, ambient temperature and road surface temperature. As the temperature of the tire changes, air in the tire expands and contracts, changing the tire's air pressure. The cold tire pressure for all Toyota models will vary and will need to be adjusted accordingly. "Cold" tire pressure, as shown on the tire pressure label on our vehicles, is generally considered to be the pressure in a tire that has not been driven in the past 4 hours and has been parked outdoors. The TPWS MUST be initialized with the tire pressure marked on the vehicle placard. Tires are then adjusted according to the information in this bulletin to ensure that the TPWS light does not illuminate unnecessarily. Page 4328 Air Flow Meter/Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION 1. INSTALL MASS AIR FLOW METER (a) Install the MAF meter with the 2 screws. Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf) (b) Connect the MAF connector. Page 7816 Control Module HVAC: Diagrams A/C Amplifier Disassembly Parking Brake Warning Switch: Service and Repair Disassembly PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and switch. Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 6536 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 9258 From 11/2009 ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): REASSEMBLY REAR DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Connect the 2 cables to the inside handle. (b) Attach the inside handle's knob to the door trim board. (c) Attach the 9 clips to install the door trim board. (d) Install the inside handle and door trim board to the door trim panel with the screw. (e) Install the door trim board to the door panel with the screw (f) Attach the clip. 2. INSTALL REAR DOOR ARMREST COVER LH 3. INSTALL REAR DOOR FRAME GARNISH LH (a) Attach the 4 clips to install the rear door frame garnish. Page 7944 * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. (d) Remove the lower No. 1 instrument panel airbag See: Removal and Replacement/Driver Side Knee Airbag Assembly/Removal. (e) Install SST. (1) Connect SST connector to the lower No. 1 instrument panel airbag. SST : 09082-00700 SST : 09082-00780 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (2) Install the lower No. 1 instrument panel airbag See: Removal and Replacement/Driver Side Knee Airbag Assembly/Installation. NOTICE: Take care not to damage SST wire harness. (3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window. (4) Maintaining enough clearance for SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage SST wire harness. (5) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal. (f) Deploy the airbag. Page 2197 Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL 1. REMOVE ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Disconnect the receiver connector. (b) Remove the bolt and receiver. Components Rear Fender Liner: Service and Repair Components EXTERIOR: FENDER LINER (for Rear Side): COMPONENTS Page 3140 (4) for Fuel Pipe Clamp Type: Install the fuel pipe clamp to the connector. (5) for Fuel Hose Connector Cover Type: Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration. (6) Check that there is no fuel leakage. 3. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system See: Fuel Delivery and Air Induction/Testing and Inspection. Page 3607 Engine Bank Identification Page 292 Relay Box: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 7738 Evaporator Temperature Sensor / Switch: Service and Repair Reassembly AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: REASSEMBLY 1. INSTALL NO. 1 COOLER THERMISTOR NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted. (a) Install the sensor to a location that is 1 fin to the right or left of its previous location. 2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (a) Install the evaporator to the blower case (front side). (b) Install the blower case (back side). Components Variable Valve Timing Actuator: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS Page 701 Page 8212 is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) for Passenger's Seat only: Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Front Seat Outer Belt Assembly (for Regular Cab) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): INSPECTION 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY CAUTION: Do not disassemble the retractor. (a) Before installing the seat belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) for Passenger's Seat only: Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Rear Center Seat Outer Belt Assembly (for Double Cab) SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION 1. INSPECT CENTER REAR SEAT OUTER BELT ASSEMBLY Page 2964 Oxygen Sensor: Diagrams Heated Oxygen Sensor Locations Temperature Sensor/Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 8169 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY Page 5621 Steering Angle Sensor: Service and Repair Installation BRAKE CONTROL: STEERING ANGLE SENSOR: INSTALLATION 1. INSTALL STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 2. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 3. INSTALL UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 4. INSTALL LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 5. ADJUST SPIRAL CABLE See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Installation 6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 7. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 8. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 9. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 7050 Standard wheel angle (unloaded vehicle): for Double Cab of Long Deck Page 6970 "Case2" 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 5941 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 6788 "Case2" 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 2737 Body Control Module: Locations LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 4692 Transmission Position Switch/Sensor: Diagrams Page 7504 Tire Pressure Warning Reset Switch: Diagrams Page 7233 Power Steering Pressure Switch: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT POWER STEERING OIL PRESSURE SWITCH (a) Check the oil pressure switch. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch on. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering pressure. (5) Start the engine. (6) Operate the steering wheel while idling, and read the value on the Techstream. Standard: (7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Inspect the power steering system See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Page 9405 (b) Remove the 2 bolts. (c) Remove the 10 bolts. (d) Pull the radiator grille to detach the 5 clips and remove the radiator grille. 2. REMOVE LOWER RADIATOR GRILLE BRACKET LH (a) Remove the bolt and nut. (b) Detach the clip and remove the lower radiator grille bracket. 3. REMOVE LOWER RADIATOR GRILLE BRACKET RH HINT Use the same procedures described for the LH side. Page 6289 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Locations Fuse: Locations Engine Room R/B, J/B - Engine Compartment Left Page 7284 (b) for 3UR-FBE: Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation. (c) for 1UR-FE: Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation. (d) for 3UR-FE: Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation. 7. INSTALL FRONT WHEEL 8. BLEED POWER STEERING FLUID (for 1GR-FE) See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 9. BLEED POWER STEERING FLUID (for 1UR-FE) See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 10. BLEED POWER STEERING FLUID (for 3UR-FE, 3UR-FBE) See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 11. CHECK POWER STEERING FLUID LEVEL (for 1GR-FE) See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 12. CHECK POWER STEERING FLUID LEVEL (for 1UR-FE) See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 13. CHECK POWER STEERING FLUID LEVEL (for 3UR-FE, 3UR-FBE) See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 14. INSPECT FOR POWER STEERING FLUID LEAK 15. PLACE FRONT WHEELS FACING STRAIGHT AHEAD HINT Perform this procedure with the front of the vehicle jacked up. 16. ADJUST FRONT WHEEL ALIGNMENT (a) Adjust the front wheel alignment See: Alignment/Service and Repair. Spiral Cable Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable Page 5176 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Page 3776 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Page 9294 Page 6156 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 8209 Seat Belt: Testing and Inspection Front Seat Outer Belt Assembly (for Double Cab) SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY CAUTION: Do not disassemble the retractor. (a) Before installing the seat belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) for Passenger's Seat only: Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Page 6203 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab) 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal Front Brake Flexible Hose Brake Hose/Line: Service and Repair Front Brake Flexible Hose Components BRAKE: FRONT BRAKE FLEXIBLE HOSE: COMPONENTS Removal BRAKE: FRONT BRAKE FLEXIBLE HOSE: REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface. 3. REMOVE FRONT FLEXIBLE HOSE (a) Remove the brake tube and wheel cylinder tube from the flexible hose with a union nut wrench while holding the flexible hose with a wrench. NOTICE: * Do not bend or damage the brake tube and wheel cylinder tube. * Do not allow any foreign matter such as dirt and dust to enter the brake tube and wheel cylinder tube from the connecting points. (b) Remove the 2 clips (labeled A) and flexible hose. Installation BRAKE: FRONT BRAKE FLEXIBLE HOSE: INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT FLEXIBLE HOSE (a) Attach 2 new clips (labeled A) to the flexible hose. Page 1295 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Locations Fuel Pump Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6044 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Components Parking Assist Switch: Service and Repair Components PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: COMPONENTS Page 8262 (b) Remove the seat belt as shown in the illustration. 17. REMOVE CENTER REAR SEAT OUTER BELT ASSEMBLY (a) Remove the 3 nuts and belt sensor. (b) Remove the nut and bolt, and then remove the outer belt. Installation SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for CrewMax): INSTALLATION 1. INSTALL CENTER REAR SEAT OUTER BELT ASSEMBLY (a) Install the outer belt with the bolt and nut. HINT Page 1991 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 1584 Transmission Speed Sensor: Diagrams Page 4598 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Components Engine Temperature Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: COMPONENTS Components Power Steering Pressure Switch: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: COMPONENTS Locations Overdrive Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Front Seat Side Airbag Assembly (except Fold Down Seat Type) Air Bag: Testing and Inspection Front Seat Side Airbag Assembly (except Fold Down Seat Type) SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold Down Seat Type): ON-VEHICLE INSPECTION 1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat with a new one: Cuts, minute cracks or marked discoloration on the front seatback around the front seat side airbag. 2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat side airbag with a new one: * Cuts, minute cracks or marked discoloration on the front seat side airbag. * Cracks or other damage to the wire harness or connector. CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow the correct procedure. Page 8298 ^ Part Number Information ^ Owner Instructions ^ Seat Belt Extender Worksheet Warranty Information Ordering Procedure 1. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSIB and copies the worksheet. 2. Dealer measures the customer and completes the worksheet. Dealer determines the correct part number and places an order for the part through Dealer Daily. 3. Dealer receives Seat Belt Extender and calls the customer to check the fit of the part. 4. If the Seat Belt Extender fit is good, dealership personnel complete the Customer Information Label attached to the part, explains usage of the part, and gives the customer a copy of the completed worksheet. Page 2059 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 3695 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 3874 Page 1322 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 5747 (a) Using a union nut wrench, disconnect the brake tube (labeled B) from the brake master cylinder. 5. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (a) Remove the 2 nuts and brake master cylinder from the brake booster. NOTICE: * The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped. * Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means. * When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or with its tip facing downward (the piston faces upward) to prevent the master cylinder piston from falling out. * Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth, and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston. * Do not use any other type of grease or fluid. * Be careful not to damage the brake tubes. (b) Remove the brake master cylinder seal from the brake master cylinder. Installation BRAKE: BRAKE MASTER CYLINDER: INSTALLATION 1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (a) Install a new brake master cylinder seal onto the brake master cylinder. (b) Install the brake master cylinder with 2 new nuts. Torque : 25 Nm (255 kgf-cm, 18 ft-lbf) 2. CONNECT FRONT NO. 1 BRAKE TUBE (a) Using a union nut wrench, connect the brake tube (labeled A) to the brake master cylinder. without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) with union nut wrench - Torque : 18 Nm (186 kgf-cm, 13 ft-lbf) Page 1692 *: for 5 leaf spring Standard Steering Angle Inclination for Regular Cab of Standard Deck Page 3190 Page 8988 11. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 933 Evaporator Temperature Sensor / Switch: Service and Repair Disassembly AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: DISASSEMBLY 1. REMOVE AIR CONDITIONING UNIT (a) Remove the air conditioning unit See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Removal. 2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY (a) Detach the 4 claws and remove the nozzle. 3. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (a) Detach the 4 claws and remove the duct. 4. REMOVE AIR FILTER COVER PLATE (a) Detach the 2 clips and remove the plate. 5. REMOVE CLEAN AIR FILTER Page 7836 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL AMBIENT TEMPERATURE SENSOR (a) Attach the clamp to install the ambient temperature sensor. (b) Connect the connector. Page 3418 (1) For Column Shift Type, refer to the following procedures See: Heating and Air Conditioning/Control Assembly/Service and Repair/Air Conditioning Panel (for Column Shift Type)/Removal. (2) For Floor Shift Type, refer to the following procedures See: Heating and Air Conditioning/Control Assembly/Service and Repair/Air Conditioning Panel (for Floor Shift Type)/Removal. (b) Check that the malfunction disappears. OK: Malfunction disappears. NG -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY See: Heating and Air Conditioning/Control Module HVAC/Service and Repair/Removal OK -- END (INTEGRATION CONTROL AND PANEL ASSEMBLY IS DEFECTIVE) Open In One Side of CAN Branch Line CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Open in One Side of CAN Branch Line - Open in One Side of CAN Branch Line DESCRIPTION If 2 or more ECUs and/or sensors do not appear on the Techstream's "CAN Bus Check" screen, one side of the CAN branch wire may be open. (One side of the CANH [branch wire]/CANL [branch wire] of the ECU and/or sensor is open.) HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU WIRING DIAGRAM Page 9174 Up to 11/2009 Brake Fluid Pressure Sensor/Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Air Fuel Ratio Sensor Oxygen Sensor: Diagrams Air Fuel Ratio Sensor Page 1486 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 327 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 5958 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 3450 NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG SENSOR (CANH, CANL) OK -- REPLACE CENTER AIRBAG SENSOR 19. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) OK -Continue to next step. 20. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - BUS BUFFER ECU) NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)". (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (BUS BUFFER ECU) OK -- Continue to next step. 21. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU) Page 8903 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL 1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE FRONT DOOR SCUFF PLATE RH Page 2982 Power Steering Pressure Switch: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT POWER STEERING OIL PRESSURE SWITCH (a) Check the oil pressure switch. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch on. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering pressure. (5) Start the engine. (6) Operate the steering wheel while idling, and read the value on the Techstream. Standard: (7) If not as specified, check for DTCs See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Inspect the power steering system See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Page 4532 Ignition Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY (a) Remove the engine room relay block cover. (b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room relay block. HINT Tape the screwdriver tip before use. (c) Disconnect the 3 connectors. 2. INSPECT INTEGRATION RELAY (IG2) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the IG2 MAIN fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the IG2 MAIN fuse. (b) Measure the resistance of the ignition relay No. 2 (IG2). Page 1168 Engine Temperature Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Partially immerse the sensor in water and warm up the water. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the engine coolant temperature sensor. NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. HINT If the result is as specified, do not replace the engine coolant temperature sensor. Page 5198 SST : 09240-00020 Standard clearance: 4. TEMPORARILY INSTALL INBOARD JOINT BOOT (a) Temporarily install 2 new boot clamps and a boot to the outboard joint shaft. 5. INSTALL INBOARD JOINT SHAFT (a) Install the cage to the outboard joint shaft. NOTICE: Insert the cage with its smaller inner diameter side facing the outboard joint. (b) Align the matchmarks placed before removal. (c) Install the inner race. (d) Using a snap ring expander, install a new snap ring. (e) Align the matchmarks placed before removal, and install the cage to the inner race. Airbag System Air Bag Deactivation Switch: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Locations Solar Sensor: Locations AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 1459 2. INSTALL FRONT SEAT ASSEMBLY LH (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Installation. 3. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 3870 Transmission Position Switch/Sensor: Diagrams Page 2430 ^ 1AR-FE (Highlander Venza) ^ 2AR-FE (RAV4 Camry) Warranty Information Required Tools & Equipment Page 8775 Front Door Tweeter Front Side Speaker Page 7103 Tire Pressure Module: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Up to 11/2009 Steering Angle Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 767 * The zero point calibration is performed only once after the system enters test mode. * Calibration cannot be performed again until the stored data is cleared once. (2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased. (3) Turn the ignition switch OFF. 4. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING SST CHECK WIRE) (a) Turn the ignition switch to ON. (b) Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more within 8 seconds. SST : 09843-18040 (c) Check that the SLIP indicator light comes on. (d) Using a check wire, perform the zero point calibration of the deceleration sensor. 5. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND DECELERATION SENSOR (WHEN USING SST CHECK WIRE) NOTICE: * While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it stationary. (Do not start the engine.) * While obtaining the zero point, do not depress the brake pedal. * Obtain the zero point on a level surface (with an inclination of 1° or less). (a) Enter Test Mode. (1) Turn the ignition switch off. (2) Check that the shift lever is in parking or neutral and apply the parking brake. CAUTION: Application of the parking brake is not necessary for entering test mode. However, apply the parking brake for safety. (3) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3. SST : 09843-18040 (4) Turn the ignition switch to ON. NOTICE: Do not start the engine. (b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor. Page 6978 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 3367 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 9215 Disassembly ENGINE HOOD / DOOR: FRONT DOOR (for Double Cab): DISASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH Page 6633 (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL POWER OUTLET SOCKET ASSEMBLY (a) Attach the claw to install the power outlet socket. 3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) Page 9033 Trailer Connector: Connector Views Page 5921 Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Connect the speed sensor connector (labeled C). NOTICE: Securely connect the connector. 4. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Installation 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 6049 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 1398 Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 6254 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 9126 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 2168 Tire Pressure Warning Reset Switch: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING RESET SWITCH (a) Disconnect the switch connector. (b) Detach the 2 claws and remove the reset switch. Page 666 (b) If the result is not as specified, replace the control switch assembly. Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 4909 / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 7. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CONSOLE BOX CARPET 10. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 11. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 12. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY (a) Move the shift lever to N. (b) Disconnect the transmission control cable end from the shift lever. (c) Remove the clip and disconnect the transmission control cable from the shift lever retainer. (d) Disconnect the 2 connectors. (e) Remove the 4 bolts and floor shift. Installation A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type): INSTALLATION Page 8110 Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 4. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 6. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 8. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 9. REMOVE FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 10. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Components Fuel Injector: Service and Repair Components 1UR-FE FUEL: FUEL INJECTOR: COMPONENTS Page 4064 (1) Remove the air hose between ports A and B. (2) Connect the pressure gauge to the vent port of the canister. (3) With port B, purge port and the air inlet port closed and port A open, apply 19.6 kPa (0.2 kgf/cm2, 2.81 psi) of pressurized air into the vent port, and then confirm that pressure is retained for 1 minute. If the result is not as specified, replace the canister assembly. (e) Check the leak detection pump. (1) Remove the detection pump from the canister. (2) Check that air flows from port A to B and then to C. If the result is not as specified, replace the canister assembly. (3) Connect the positive (+) lead of the battery to terminal 7 and the negative (-) lead to terminal 6. (4) Check that the valve is closed. If the result is not as specified, replace the canister assembly. (5) Install the detection pump. Page 6538 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 3878 Variable Valve Timing Actuator Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION 1. INSTALL VVT SENSOR (a) Install the 4 sensors with the 4 bolts. Page 5979 Ignition Switch: Service and Repair Removal 1UR-FE STARTING: IGNITION SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal. (b) for Manual Tilt and Manual Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal. (c) for Power Tilt and Power Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal. 3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Disassembly 4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly 5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly 6. REMOVE IGNITION SWITCH ASSEMBLY (a) Detach the 2 claws and remove the ignition switch from the steering lock. Page 6347 Push the terminal retainer down to the temporary lock position. Page 7596 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 7371 Suspension Strut / Shock Absorber: Overhaul Disassembly SUSPENSION: FRONT SHOCK ABSORBER: DISASSEMBLY 1. REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT (a) Using SST, compress the coil spring. SST : 09727-30021 09727-00010 09727-00021 09727-00031 NOTICE: * Make sure that the suspension support is free from the coil spring. * Do not compress the coil spring more than necessary. * Do not use an impact wrench. It will damage SST. * Do not place yourself over the top of the shock absorber. CAUTION: Be careful as the coil spring may spring upward and cause an injury. (b) Remove the front support to front shock absorber nut. 2. REMOVE FRONT SUSPENSION SUPPORT SUB-ASSEMBLY LH (a) Remove the suspension support, 2 retainers and 2 cushions from the shock absorber rod. 3. REMOVE FRONT COIL SPRING LH (a) Remove the coil spring from the shock absorber. Reassembly SUSPENSION: FRONT SHOCK ABSORBER: REASSEMBLY 1. INSTALL FRONT COIL SPRING LH Page 9109 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Components BRAKE CONTROL: BRAKE ACTUATOR: COMPONENTS Removal BRAKE CONTROL: BRAKE ACTUATOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. DISCONNECT VSC ACTUATOR CONNECTOR (a) Pull the release bar and disconnect the VSC actuator connector. 3. REMOVE BRAKE TUBE (a) Use tags or make a note to identify the reconnection locations. Page 6038 Ignition Switch: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 687 Power Mirror Switch: Testing and Inspection MIRROR: OUTER MIRROR SWITCH: INSPECTION 1. INSPECT OUTER MIRROR SWITCH ASSEMBLY (w/o Retract Mirror) (a) Check the resistance. (1) Select "L" on the left/right adjustment switch. (2) Measure the resistance according to the value(s) in the table below. Standard resistance: (3) If the result is not as specified, replace the outer mirror switch. (4) Select "R" on the left/right adjustment switch. (5) Measure the resistance according to the value(s) in the table below. Standard resistance: (6) If the result is not as specified, replace the outer mirror switch. 2. INSPECT OUTER MIRROR SWITCH ASSEMBLY (w/ Retract Mirror) Components Tire Pressure Sensor: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS Page 8667 "Case2" 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 1333 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 8153 Seat Position Sensor: Service and Repair Installation SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: INSTALLATION 1. INSTALL SEAT POSITION SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning (c) Using a feeler gauge 1.0 mm (0.0393 in.), install the seat position sensor. NOTICE: * If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the seat position sensor with a new one. * When installing the seat position sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. HINT Be sure that the clearance between the seat position sensor and the seat rail is within 0.6 to 1.4 mm (0.0236 to 0.0551 in.). (d) Using a T30 "TORX" socket wrench, install the seat position sensor with the screw. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (e) Make sure that the clearance between the seat position sensor and the seat rail is within 0.6 to 1.4 mm (0.0236 to 0.0551 in.). (f) Check that there is no looseness in the installation parts of the seat position sensor. (g) Connect the connector. (h) Install the seat slide position sensor protector to the seat position sensor. Page 3288 ^ 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 2804 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 1815 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 2012 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 1240 Variable Valve Timing Actuator Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. REMOVE VVT SENSOR (a) Disconnect the 4 sensor connectors. (b) Remove the 4 bolts and 4 sensors. Air Fuel Ratio Sensor Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS Page 7785 Refrigerant: Service and Repair AIR CONDITIONING: REFRIGERANT: REPLACEMENT 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (a) Start up the engine. (b) Turn the A/C switch ON. (c) Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor. (d) Stop the engine. (e) Recover the refrigerant from the A/C system using a refrigerant recovery unit. 2. CHARGE REFRIGERANT SST : 09985-20010 09985-02010 09985-02050 09985-02060 09985-02070 09985-02090 09985-02110 09985-02130 09985-02150 (a) Perform vacuum purging using a vacuum pump. (b) Charge refrigerant HFC-134a (R134a). Standard: 600 +/-30 g (21.2 +/-1.1 oz.) NOTICE: Page 8773 Air Fuel Ratio Sensor Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor Components 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS Page 771 Page 3360 Components Air Flow Meter/Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS Page 4761 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 7759 Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. (b) for 1UR-FE: Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. (c) for 3UR-FE: Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. (d) for 3UR-FBE: Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair. 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 4. REMOVE NO. 2 COOLER COVER (a) Remove the 2 nuts. (b) Detach the 2 claws and remove the cover. 5. REMOVE SUCTION PIPE SUB-ASSEMBLY AND LIQUID TUBE (a) Remove the bolt. (b) Detach the plate as shown in the illustration. (c) Disconnect the suction pipe sub-assembly and liquid tube. Page 4946 ^ 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 3575 Knock Sensor: Diagrams Page 8227 (5) Disconnect the pretensioner connector as shown in the illustration. (d) Prepare SST for activation of the seat belt pretensioner. (1) Install the floor anchor of the seat belt. (2) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner. SST : 09082-00700 SST : 09082-00770 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Move SST at least 10 m (32.8 ft.) away from the front of the vehicle. (4) Close all the doors and windows of the vehicle. HINT Leave a gap in one of the windows for inserting SST wire harness. NOTICE: Take care not to damage SST wire harness. (5) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the negative (-) terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (32.8 ft.) of the vehicle. (2) Press SST activation switch to activate the seat belt pretensioner. HINT The seat belt pretensioner operates at the same time SST activation switch's LED illuminates. Page 2023 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 6841 Page 3149 Spark Plug: Service and Repair Removal 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the MAF meter connector and clamp. (b) Disconnect the ventilation hose and vacuum hose. (c) Loosen the hose clamp. (d) Remove the 2 bolts and air cleaner. 3. REMOVE IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Disconnect the 3 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Remove the 4 bolts and 4 ignition coils. (b) for Bank 2: (1) Disconnect the 2 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Disconnect the engine wire harness clamp. Page 476 Seat Occupant Classification Module - Air Bag: Diagrams Page 2710 Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) 8. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 9. INSTALL EXHAUST PIPE ASSEMBLY (a) for Regular Cab Standard Deck: Install the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation. (b) except Regular Cab Standard Deck: Install the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation. 10. CONNECT COOLER COMPRESSOR ASSEMBLY See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Installation 11. INSTALL GENERATOR ASSEMBLY (a) Install the generator See: Starting and Charging/Charging System/Alternator/Service and Repair/Removal and Replacement/Installation. 12. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (a) Apply a light coat of engine oil to a new O-ring. (b) Install the O-ring to the dipstick guide. (c) Install the dipstick guide with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (d) Install the dipstick. 13. INSTALL INTAKE MANIFOLD ASSEMBLY (a) Install the intake manifold See: Engine/Intake Manifold/Service and Repair/Installation. 14. INSPECT FOR EXHAUST GAS LEAK If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary. 15. INSTALL FRONT FENDER APRON SEAL REAR LH (a) Install the fender apron seal with the 5 clips. 16. INSTALL FRONT FENDER APRON SEAL LH (a) Install the fender apron seal with the 6 clips. 17. INSTALL FRONT FENDER APRON SEAL REAR RH (a) Install the fender apron seal with the 5 clips. 18. INSTALL FRONT FENDER APRON SEAL RH (a) Install the fender apron seal with the 6 clips. Components EGR Cooler: Service and Repair Components 1UR-FE EMISSION CONTROL: EGR COOLER: COMPONENTS Page 4601 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 3975 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 984 Door Switch: Testing and Inspection Rear Door Courtesy Switch LIGHTING: REAR DOOR COURTESY SWITCH: INSPECTION 1. INSPECT REAR DOOR COURTESY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 9068 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 6759 AJ1-AJ8 Page 8229 (c) Prepare SST for activation of the seat belt pretensioner. (1) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner. NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. (2) Place the front seat outer belt on the ground and cover it with a tire (with wheel). NOTICE: Set up the front seat outer belt as shown in the illustration. (3) Move SST at least 10 m (32.8 ft.) away from the wheel. NOTICE: Take care not to damage SST wire harness. (d) Activate the seat belt pretensioner. (1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. (2) Check that no one is within 10 m (32.8 ft.) of the wheel. (3) Press SST activation switch to activate the seat belt pretensioner. HINT The seat belt pretensioner operates at the same time SST activation switch's LED illuminates. (e) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: * Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. * Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. * Always wash your hands with water after completing the disposal. * Do not apply water to a front seat outer belt that has an activated pretensioner. (1) Remove the tire (with wheel) and SST. Page 5690 (a) Install the stop light switch mounting adjuster See: Lighting and Horns/Brake Light Switch/Service and Repair/Installation. 5. INSTALL STOP LIGHT SWITCH ASSEMBLY (a) Attach the harness clip. (b) Install the stop light switch See: Lighting and Horns/Brake Light Switch/Service and Repair/Installation. (c) Connect the stop light switch connector. 6. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (a) Install the air duct with the bolt. 7. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 9. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 10. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 11. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 12. CHECK AND ADJUST BRAKE PEDAL (a) Check and adjust brake pedal See: Adjustments. 13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 14. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL (a) Check the sensor signal See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 4462 Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION 1. CHECK MASS AIR FLOW METER (a) Check the mass air flow value. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF. (5) Blow air into the MAF meter, and check that the MAF value fluctuates. (6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102. Page 3269 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 6929 Page 8807 * The procedures listed below are for the LH side. 1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) (a) Attach the 3 claws to install the speaker to the bracket. NOTICE: Do not touch the cone part of the speaker. (b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws. 2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 4 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR ARMREST COVER LH 5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Page 2423 (f) Remove the oil filter element and O-ring from the oil filter cap. NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent damage to the cap's O-ring groove. 4. INSTALL OIL FILTER ELEMENT (a) Clean the inside of the oil filter cap, its threads and its O-ring groove. (b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap. (c) Set a new oil filter element to the oil filter cap. (d) Remove any dirt or foreign matter from the installation surface of the engine. (e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap. (f) Using SST, tighten the oil filter cap. SST : 09228-06501 Torque : 25 Nm (255 kgf-cm, 18 ft-lbf) NOTICE: * When tightening the oil filter cap, do not remove the oil filter bracket clip. * Make sure that the oil filter is installed securely as shown in the illustration. * Be careful that the O-ring does not get caught between any surrounding parts. Page 1306 Ignition Switch: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 6363 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 1817 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 3562 (a) Disconnect the J2, DB and DD ECU connectors. (b) Measure the resistance according to the value(s) in the table below. HINT * *1: for V bus * *2: for MS bus 7. CHECK ECM (a) Disconnect the A24 and D74 ECM connector. Page 9038 Connectors Part 1 Page 5282 HINT * Using the following chart, check if the calculated No. 3 joint angle is within the specified value. * The tolerance is +/-0°60' (1.00°). Standard No. 3 joint angle: *1: for 5 leaf spring *2: includes Off road package * If the measured angle is not within the specification, adjust it with the bearing washer (See "Adjust Propeller Shaft Angle"). 6. ADJUST PROPELLER SHAFT ANGLE (for 3 Joint Type) HINT If the propeller shaft angle is outside the specification or there is vibration and noise, perform the propeller shaft adjustment using the Page 3107 Knock Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION 1. INSPECT KNOCK SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the knock sensor. Page 6784 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 4046 * Make sure the paint mark of the No. 2 air injection system hose is facing upward. * Make sure the direction of the hose clamp is as shown in the illustration. (d) Connect the black colored clamp to the No. 2 air injection system hose and wire harness shown in the illustration below labeled H. Then insert the clamp's clip into the body hole. 7. CONNECT FRONT FENDER APRON SEAL RH (a) Connect the fender apron seal with the 2 clips. 8. CONNECT FRONT FENDER LINER RH (a) Connect the fender liner with the 8 clips. Page 8882 Central Control Module: Service and Repair Removal AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 3. REMOVE MULTI-MEDIA INTERFACE ECU (a) Remove the nut. (b) Disconnect the connector and remove the multi-media interface ECU. 4. REMOVE MULTI-DISPLAY CONTROLLER BRACKET A (a) Remove the 2 bolts and multi-display controller bracket A. Page 7776 7. INSTALL BLOWER CASE SUB-ASSEMBLY (a) Attach the 3 claws to install the case. (b) Install the 3 screws. 8. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. 9. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the servo motor. (1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to install the main plate. (2) Install the 2 screws. (b) Install the servo motor. Testing and Inspection Seat Heater Control Module: Testing and Inspection SEAT: SEAT HEATER CONTROL (w/ Seat Heater System or Climate Control Seat System): ON-VEHICLE INSPECTION 1. INSPECT SEAT HEATER CONTROL SUB-ASSEMBLY LH (a) Disconnect the Z11 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: (c) If the result is not as specified, there may be a malfunction on the wire harness side. (d) Measure the voltage according to the value(s) in the table below. Standard voltage: (e) If the result is not as specified, there may be a malfunction on the wire harness side. (f) Connect the Z11 connector. (g) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 1717 Standard steering axis inclination (unloaded vehicle): for Regular Cab of Long Deck Standard steering axis inclination (unloaded vehicle): for Double Cab of Standard Deck Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6606 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 592 Page 7591 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 3378 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 9265 Locations Transmission Temperature Sensor/Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 6386 Page 8152 Seat Position Sensor: Service and Repair Removal SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Removal. 2. REMOVE SEAT POSITION SENSOR (a) Using a T30 "TORX" socket wrench, remove the screw and seat position sensor with sensor protector. (b) Disconnect the connector. (c) Remove the seat slide position sensor protector from the seat position sensor. Page 1850 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). Up to 11/2009 Wheel Speed Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 3723 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 6. INSPECT IGNITION SWITCH See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0617 NG -- REPLACE IGNITION SWITCH See: Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Service and Repair/Removal OK -- Continue to next step. 7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the cable from the battery positive terminal. (c) Remove the integration relay from the engine room relay block. (d) Disconnect the integration relay connectors. Locations Fuse: Locations Engine Room R/B, J/B - Engine Compartment Left Skid Control Sensor Wire Wheel Speed Sensor: Diagrams Skid Control Sensor Wire Components Cabin Temperature Sensor / Switch: Service and Repair Components AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): COMPONENTS Page 7444 Tire Pressure Sensor: Diagrams Front Speed Sensor Wheel Speed Sensor: Service and Repair Front Speed Sensor Components BRAKE CONTROL: FRONT SPEED SENSOR: COMPONENTS Removal BRAKE CONTROL: FRONT SPEED SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT SKID CONTROL SENSOR WIRE LH (a) Disconnect the connector (labeled A) from the front speed sensor. (b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C). (c) Disconnect the connector (labeled D). Page 6088 Neutral Safety Switch: Service and Repair Removal A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL 1. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut and disconnect the cable. 2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Disconnect the switch connector. (b) Remove the nut, spring washer and transmission control shaft lever RH. (c) Using a screwdriver, bend the tabs of the lock washer. (d) Remove the lock nut and lock washer. (e) Remove the bolt and switch. Air Conditioning System (for Automatic Air Conditioning System) Control Module HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 1092 (d) Check the fog light switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: (2) If the result is not as specified, replace the headlight dimmer switch. Page 4716 Standard voltage: (3) If the voltage is not as specified, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal. If the voltage is normal, replace the 4WD control switch. Components Steering Column Control Module: Service and Repair Components STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): COMPONENTS Locations Tire Pressure Sensor: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 6338 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. Page 3421 A -- Continue to next step. 5. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH ACTUATOR BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (SKID CONTROL ECU WITH ACTUATOR) OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal 6. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR) (a) Disconnect the J6 steering angle sensor connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU) A -Continue to next step. 7. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Page 756 Sunroof / Moonroof Switch: Service and Repair Removal SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): REMOVAL 1. REMOVE ROOF CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE SLIDING ROOF SWITCH (a) Disconnect the 2 connectors. (b) Detach the clamp. (c) Remove the 7 screws and lighting housing (upper side). (d) Detach the 4 claws and remove the sliding roof switch. Page 1699 Standard vehicle height (unloaded vehicle): for Double Cab of Long Deck Standard vehicle height (unloaded vehicle): for CrewMax of standard deck Page 5074 30. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION 31. INSTALL FRONT DIFFERENTIAL CASE 32. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer. (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the differential carrier as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Standard Seal Diameter (A): 2.0 to 3.0 mm (0.0788 to 0.118 in.) HINT Install the side bearing retainer within 10 minutes of applying seal packing. (d) Install the front differential cross shaft bearing retainer and front differential front support assembly LH with the 11 bolts (A), and 3 bolts (B). for bolt A - Torque : 65 Nm (633 kgf-cm, 48 ft-lbf) for bolt B - Torque : 155 Nm (1581 kgf-cm, 114 ft-lbf) NOTICE: Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration. 33. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING (a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it. Page 7926 (b) With the front passenger airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front passenger airbag, instrument panel or instrument panel reinforcement with a new one: * Cuts, minute cracks or marked discoloration on the front passenger airbag. * Cracks or other damage to the connectors. * Deformation or cracks on the instrument panel or instrument panel reinforcement. CAUTION: For removal and installation procedures of the front passenger airbag, be sure to follow the correct procedure. Steering Pad SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: ON-VEHICLE INSPECTION 1. CHECK STEERING PAD (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) With the steering pad installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad with a new one: Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. 2. CHECK STEERING PAD (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 3396 Information Bus: Description and Operation CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: SYSTEM DIAGRAM Locations Telescoping Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Page 5392 Control Module: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 7283 Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) NOTICE: Use the formula calculate special torque values for situations for situations where a union nut wrench is combined with a torque wrench See: Service Precautions (d) Using a union nut wrench, tighten the pressure feed tube (return tube side). Torque : 25 Nm (255 kgf-cm, 18 ft-lbf) NOTICE: Use the formula calculate special torque values for situations for situations where a union nut wrench is combined with a torque wrench See: Service Precautions 3. CONNECT TIE ROD END SUB-ASSEMBLY LH (a) Connect the tie rod end LH to the steering knuckle with the nut. Torque : 69 Nm (704 kgf-cm, 51 ft-lbf) (b) Install a new cotter pin. HINT Further tighten the nut up to 60° if the holes for the cotter pin are not aligned. 4. CONNECT TIE ROD END SUB-ASSEMBLY RH HINT Use the same procedures described for the LH side. 5. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (a) Align the matchmarks on the No. 2 steering intermediate shaft and power steering gear. (b) Install the bolt. Torque : 35 Nm (360 kgf-cm, 26 ft-lbf) 6. INSTALL ENGINE ASSEMBLY (a) for 1GR-FE: Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation. Airbag Cutoff Switch Air Bag Deactivation Switch: Diagrams Airbag Cutoff Switch Page 386 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK Page 8014 (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Locations Ignition Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 2026 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 7065 (c) Read the adjustment chart (example). (1) Find the wheel alignment standard value applicable for the particular model. (2) Mark the selected standard value on the adjustment chart. Standard value (reference): (3) Mark the alignment value measured when the vehicle is unloaded on the adjustment chart. Measured value (reference): (4) As shown in the chart, read the distance from the marked point to 0, and adjust the front and/ or rear adjusting cams accordingly. Amount to turn adjusting cams (by gradation): Up to 11/2009 Hydraulic Control Assembly - Antilock Brakes: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 970 Standard resistance: (b) If the result is not as specified, replace the rheostat. Page 3904 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 4959 Install the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation. 9. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 10. ADJUST AUTOMATIC TRANSMISSION FLUID LEVEL (a) Adjust the automatic transmission fluid level See: Service and Repair/Procedures. 11. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 12. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 13. INSPECT FOR AUTOMATIC TRANSMISSION FLUID LEAK Page 3780 Air Flow Meter/Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL 1. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF connector. (b) Remove the 2 screws and MAF meter. Page 7621 Cabin Temperature Sensor / Switch: Service and Repair Installation AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): INSTALLATION 1. INSTALL ROOM TEMPERATURE SENSOR (a) Attach the 2 claws to install the sensor. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 3. INSTALL INSTRUMENT SIDE PANEL LH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 5. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Page 6787 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 7158 Tire Pressure Warning Reset Switch: Diagrams Page 5677 * Low pedal or spongy pedal. * Brake pedal is depressed firmly but braking is insufficient. (c) Check and adjust brake fluid level in reservoir See: Hydraulic System/Brake Fluid/Testing and Inspection. 2. BLEED BRAKE SYSTEM (a) Bleed brake master cylinder HINT If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder. (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Using a union nut wrench, disconnect the 2 brake lines from the master cylinder. (4) Slowly depress and hold the brake pedal. (5) Block the outer holes with your fingers, and release the pedal. (6) Repeat the 2 previous steps 3 or 4 times. (7) Using a union nut wrench, connect the 2 brake lines to the master cylinder. without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) with union nut wrench - Torque : 18 Nm (185 kgf-cm, 13 ft-lbf) * Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). * This torque value is effective when union nut wrench is parallel to the torque wrench. (b) Bleed brake line (1) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (3) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (4) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (5) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (6) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (7) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. Page 7382 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 6516 Page 1554 Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: * No further tightening is required once the nut is tightened with the specified torque. * Check that there is no foreign matter on the washer and nut. * Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve, washer and nut. Failing to do so may result in improper installation. (d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main body of the tire pressure warning valve and transmitter in the shaded area as shown in the illustration. NOTICE: * If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will interfere with the tire pressure warning valve and transmitter, and may cause damage to it. * If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the tire pressure warning valve and transmitter. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is not clamped by the bead. (f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: Page 5588 Braking Sensor/Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6188 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 10. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL POWER OUTLET SOCKET COVER Page 9213 Page 7263 Steering Column Control Module: Service and Repair Installation STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): INSTALLATION 1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU (a) Install the ECU with the 2 screws. Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Installation 6. INSTALL LOWER STEERING COLUMN COVER (a) Attach the 2 claws to install the steering column lower cover. 7. INSTALL UPPER STEERING COLUMN COVER Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Control Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 2900 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Body - Tube Step Step Pad Lifting/Cracking Auxiliary Step / Running Board: All Technical Service Bulletins Body - Tube Step Step Pad Lifting/Cracking T-SB-0164-10 June 28, 2010 Tube Step - Step Pad Lifting/Cracked Service Category Vehicle Exterior Section Exterior Panels/Trim Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a condition where the step pad has lifted or cracked. To improve the serviceability of the tube step the step pad is now available as a separate service part. Follow the procedure in this bulletin to replace the step pad. Removal of the tube step is not required to perform step pad replacement. Parts Information Warranty Information APPLICABLE WARRANTY ^ Toyota accessories installed as original equipment are 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. ^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months, regardless of mileage, from the date of installation on the vehicle, or the remainder of the applicable New Vehicle Limited Warranty, whichever provides the greater coverage. ^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of purchase. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Repair Procedure Locations Neutral Safety Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 3366 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 992 (b) Disconnect the connector and remove the courtesy switch. Installation LIGHTING: REAR DOOR COURTESY SWITCH: INSTALLATION HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL REAR DOOR COURTESY SWITCH (a) Connect the connector. (b) Install the courtesy switch with the bolt. Page 6731 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 2316 NOTICE: * Remove any oil from the contact surface. * Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. (c) Install the camshaft housing, and install the 18 bolts in the order shown in the illustration. for bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) except bolt A - Torque : 30 Nm (306 kgf-cm, 22 ft-lbf) NOTICE: * Do not start the engine for at least 2 hours after the installation. * Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing. (d) Tighten the 10 bolts in the order shown in the illustration. Torque : 16 Nm (163 kgf-cm, 12 ft-lbf) NOTICE: Thoroughly wipe clean any seal packing. 3. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (a) Install the chain tensioner with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to fix it in place. 4. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH Components Alarm Module: Service and Repair Components THEFT DETERRENT: THEFT WARNING ECU: COMPONENTS Page 1326 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 640 (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY Page 991 Removal LIGHTING: REAR DOOR COURTESY SWITCH: REMOVAL HINT * Use the same procedures for the RH and LH side. * The procedures listed below are for the LH side. 1. REMOVE REAR DOOR COURTESY SWITCH (a) Remove the bolt. Page 4018 4. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 7995 Removal SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE LOWER NO. 3 STEERING WHEEL COVER (a) Using a screwdriver, remove the steering wheel cover. Page 7737 (a) Remove the packing. (b) Remove the 6 screws and detach the 4 claws. (c) Remove the blower case (back side). (d) Remove the evaporator from the blower case (front side). 17. REMOVE NO. 1 COOLER THERMISTOR (a) Remove the No. 1 cooler thermistor. Page 406 (b) Install the connector holder block cover. 4. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Installation 5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 6843 Page 6109 (b) Inspect the load of the brush spring. (1) Take a pull scale reading immediately after the brush spring separates from the brush. Standard spring load: 22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf) Minimum spring load: 12 N (1 kgf, 2.8 lbf) (2) If the load is less than the minimum, replace the starter brush holder assembly. 5. INSPECT STARTER YOKE ASSEMBLY (a) Inspect the resistance of the field coil. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, repair or replace the starter yoke assembly. (3) Measure the resistance according to the value(s) in the table below. Standard Resistance: (4) If the result is not as specified, repair or replace the starter yoke assembly. 6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Check the gear teeth of the planetary gears and starter center bearing clutch for wear or damage. If any planetary gear is damaged, replace the planetary gear assembly. If any teeth of the starter center bearing clutch are damaged, replace the starter center bearing clutch sub-assembly. Page 460 Removal SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY Page 6166 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 36 Collision Avoidance Module: Diagrams Page 8084 Page 1875 Refer to the Technical Information System (TIS) when replacing the oil filter applicable model and model year Repair Manual: Components Sunroof / Moonroof Switch: Service and Repair Components SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): COMPONENTS Page 6324 JJ1-JL1 Page 2418 Refer to the Technical Information System (TIS) when replacing the oil filter applicable model and model year Repair Manual: Page 6636 Installation OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION 1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply) (a) Attach the 2 claws to install the power outlet socket. 2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard) (a) Attach the 2 claws to install the power outlet socket cover. 3. INSTALL REAR POWER OUTLET SOCKET (for Standard) (a) Attach the claw to install the power outlet socket. 4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL Page 6933 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 7559 Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 2038 Fuse Block: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Center Speaker Speaker: Diagrams Center Speaker Page 4753 ^ 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 Diagrams Steering Angle Sensor: Diagrams Page 3511 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU (CANH, CANL) OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal 18. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR) (a) Disconnect the J46 center airbag sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Components Exhaust Manifold: Service and Repair Components 1UR-FE EXHAUST: EXHAUST MANIFOLD: COMPONENTS Page 1445 Seat Occupant Sensor: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 4275 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 8324 (b) Detach the 2 claws and remove the switch. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: INSTALLATION 1. INSTALL CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Attach the 2 claws to install the switch. (b) Connect the connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 1552 Tire Pressure Sensor: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL 1. REMOVE TIRE 2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Remove the valve core and cap, and release the air from the tire. (b) After ensuring that a sufficient amount of air has been released, remove the nut and washer that is used to secure the tire pressure warning valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire. HINT Keep the removed cap, valve core, nut and washer. (c) Disengage the bead using the shoe of a tire remover. NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due to interference between the sensor and tire bead. (d) Remove the bead on the upper side. (e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on the lower side. HINT * The grommet is a non-reusable part. * Check that there are no cracks or damage on the grommet. If any damage is found, replace the washer and nut. Stereo Jack Adapter Assembly Auxiliary Input / Output Jack: Diagrams Stereo Jack Adapter Assembly Page 6259 Page 4337 (3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. (4) Pinch the connector and disconnect the connector and pipe. (5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out. NOTICE: Do not use any tools. (6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. (7) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag. (e) Observe these precautions when connecting the fuel tube connector (for Quick Type). (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe. (3) After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected. Page 3435 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU (CANH, CANL) OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal 18. CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR) (a) Disconnect the J46 center airbag sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG SENSOR (CANH, CANL) OK -- REPLACE CENTER AIRBAG SENSOR 19. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) (a) Measure the resistance according to the value(s) in the table below. Page 8672 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 7497 Tire Pressure Sensor: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so that the print surface can be seen. NOTICE: * Check that there is no visible deformation, damage or other abnormalities on the tire pressure warning valve and transmitter. * Check that there is no foreign matter on the inner grommet and around the rim hole. * If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be damaged or fail to transmit signals when running at a high speed. * If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before installation. * The transmitter ID registration must be performed for all tire pressure warning valve and transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do not need to be replaced before performing the transmitter ID registration See: Testing and Inspection/Programming and Relearning/Registration * It is necessary to perform initialization See: Testing and Inspection/Programming and Relearning/Initialization after registration See: Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been replaced. (b) If reusing the tire pressure warning valve and transmitter: Install a new grommet. HINT A new tire pressure warning valve and transmitter is supplied with a grommet. (c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut. Air Conditioning System (for Automatic Air Conditioning System) Compressor Clutch Relay: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 423 Fuel Pump Control Unit: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Horn Switch: Locations HORN: HORN SYSTEM: PARTS LOCATION Page 6620 Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. See: Locations Specifications Compression Check: Specifications COMPRESSION Page 7937 (1) Place at least 2 tires under the tire which the front seat side airbag is tied to. (2) Place at least 2 tires over the tire which the front seat side airbag is tied to. The top tire should have the disc wheel installed. NOTICE: * Do not place SST connector under the tire because it could be damaged. * As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. * As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (f) Install SST. (1) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the front seat side airbag is tied to. (3) Press SST activation switch and deploy the airbag. Page 2064 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 3709 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 8213 (a) Check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Rear Seat Outer Belt Assembly (for CrewMax) SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): INSPECTION 1. INSPECT REAR SEAT OUTER BELT ASSEMBLY (a) Check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt assembly. (b) Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically start to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If the operation is not as specified, replace the belt assembly. Rear Seat Outer Belt Assembly (for Double Cab) SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION 1. INSPECT REAR SEAT OUTER BELT ASSEMBLY Air Fuel Ratio Sensor Oxygen Sensor: Diagrams Air Fuel Ratio Sensor Page 1608 Four Wheel Drive Selector Switch: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION 1. INSTALL 4WD CONTROL SWITCH (a) Attach the 3 claws to install the switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 8816 * The procedures listed below are for the LH side. 1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) (a) Attach the 3 claws to install the speaker to the bracket. NOTICE: Do not touch the cone part of the speaker. (b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws. 2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 4 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 4. INSTALL FRONT DOOR ARMREST COVER LH 5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Page 8540 Page 1709 (b) Inspect the camber, caster and steering axis inclination. Standard camber inclination (unloaded vehicle): for Regular Cab of Standard Deck Standard camber inclination (unloaded vehicle): for Regular Cab of Long Deck Standard camber inclination (unloaded vehicle): for Double Cab of Standard Deck Page 8276 Components SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): COMPONENTS Page 2824 (c) WAVEFORM 2: HINT The wavelength varies in accordance with the engine operating conditions. (d) WAVEFORM 3: HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the heated oxygen sensor. (e) WAVEFORM 4: Air Conditioning Panel (for Column Shift Type) Control Assembly: Service and Repair Air Conditioning Panel (for Column Shift Type) Components AIR CONDITIONING: AIR CONDITIONING PANEL (for Column Shift Type): COMPONENTS Page 2028 Engine Room R/B, J/B - Engine Compartment Left Page 1419 Page 8370 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 8980 (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE COWL SIDE TRIM BOARD LH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY Page 8292 Seat Belt Buckle Switch: Diagrams Page 335 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 6173 Connectors Locations: The locations of components, connectors, ground points, and splices referred to within these diagrams can be found at Vehicle Locations. See: Locations Power Outlet [12V] Page 5411 Standard voltage: (3) If the voltage is not as specified, replace the 4WD control ECU See: Control Module/Service and Repair/Removal. If the voltage is normal, replace the 4WD control switch. Page 4315 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 5950 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 9059 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 2382 Drive Belt: Service and Repair Installation 1UR-FE ENGINE MECHANICAL: DRIVE BELT: INSTALLATION 1. INSTALL FAN AND GENERATOR V BELT (a) Set the V belt onto every part. (b) While turning the belt tensioner counterclockwise, remove the pin. NOTICE: Make sure that the V belt is properly set to each pulley. (c) After installing the belt, check that it fits properly in the ribbed grooves. HINT Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley. 2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and Repair/Replacement 3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 9053 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Transmission Control Switch Transmission Mode Switch: Diagrams Transmission Control Switch Page 8387 (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. (e) Connect the holder (with connectors). (f) Check that the waterproof sheet is properly set. 2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 2304 1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): REMOVAL 1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Removal. 2. SET NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and Repair/Overhaul/Disassembly 3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole. (c) Remove the 2 bolts, chain tensioner and gasket. 4. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH 5. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH (a) Remove the 2 bolts and chain vibration damper. 6. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH (a) While pushing down the No. 3 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to fix it in place. Page 649 Heated Mirror Switch: Locations Power Mirror Control System (w/o Memory) MIRROR: POWER MIRROR CONTROL SYSTEM (w/o Memory): PARTS LOCATION Page 1325 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 817 Traction Control Switch: Diagrams Page 3042 Camshaft Position Sensor: Diagrams Page 8564 Parking Assist Control Module: Service and Repair Installation PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: INSTALLATION HINT A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL CLEARANCE WARNING ECU ASSEMBLY (a) Install the clearance warning ECU to the bracket with the 2 nuts. NOTICE: * Avoid any impact to the clearance warning ECU. * Do not drop the ECU. If it is dropped, replace it with a new one. 2. INSTALL CLEARANCE WARNING ECU WITH BRACKET (a) Install the ECU with bracket with the nut and bolt. (b) Connect the ECU connectors and attach the harness clamp. NOTICE: Do not apply excessive force to the wire harnesses. 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation 5. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation. Locations Tire Pressure Warning Reset Switch: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 5273 (a) Place matchmarks on the propeller shaft flange and differential flange. (b) Remove the 4 bolts and 4 nuts. (c) w/o Bearing Washer: (1) Remove the 2 mounting bolts from the frame crossmember. (d) w/ Bearing Washer: (1) Remove the 2 mounting bolts and 2 bearing washers from the frame crossmember. (e) Place matchmarks on the propeller shaft flange and transfer flange. (f) Remove the 4 nuts and propeller shaft. Installation PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): INSTALLATION 1. INSTALL PROPELLER SHAFT ASSEMBLY (for 2 Joint Type) HINT When replacing the spider bearing, make sure that the grease fitting assembly hole is facing in the direction shown in the illustration. Page 6505 Driver Side J/B Inner Circuit Page 8641 Television / Monitor: Service and Repair Video Terminal (for Separate Seat Type) Components AUDIO / VISUAL: VIDEO TERMINAL (for Separate Seat Type): COMPONENTS Removal AUDIO / VISUAL: VIDEO TERMINAL (for Separate Seat Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 2282 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Page 3491 (a) Reconnect the J86 No. 1 junction connector connector. NEXT -- Continue to next step. 4. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR) (a) Disconnect the J113 No. 2 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) OK -- Continue to next step. 5. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) (a) Disconnect the J94 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step. 6. CONNECT CONNECTOR (a) Reconnect the J94 No. 1 junction connector connector. (b) Reconnect the J113 No. 2 junction connector connector. Page 7573 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 7129 Power Steering Pressure Switch: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install a new O-ring to the power steering oil pressure switch. (b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch. NOTICE: * When reusing the power steering oil pressure switch, inspect the O-ring. * If the O-ring has scratches or cuts, replace the power steering oil pressure switch. (c) Using SST, install the power steering oil pressure switch. SST : 09922-10010 without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the torque wrench are connected in a straight line. (d) Connect the oil pressure switch connector. 2. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 3. ADD POWER STEERING FLUID 4. BLEED POWER STEERING FLUID See: Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 5. INSPECT FOR POWER STEERING FLUID LEAK 6. CHECK FLUID LEVEL See: Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 8. INSTALL FRONT WHEEL See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Page 2492 10. INSTALL FAN SHROUD See: Cooling System/Radiator Cooling Fan/Service and Repair/Installation 11. INSTALL FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 12. INSTALL INLET RADIATOR HOSE See: Cooling System/Radiator Cooling Fan/Service and Repair/Installation 13. ADD ENGINE COOLANT See: Cooling System/Coolant/Service and Repair 14. INSPECT FOR COOLANT LEAK See: Cooling System/Testing and Inspection 15. INSPECT FOR OIL LEAK See: Engine Lubrication/Engine Oil/Service and Repair/Replacement 16. CHECK ENGINE OIL LEVEL See: Engine Lubrication/Testing and Inspection 17. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and Repair/Replacement 18. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 1494 Page 359 ^ 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 6056 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Specifications Engine Oil Pressure: Specifications ENGINE OIL PRESSURE Page 434 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection Page 6989 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Page 8548 Central Control Module: Service and Repair Removal AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 3. REMOVE MULTI-MEDIA INTERFACE ECU (a) Remove the nut. (b) Disconnect the connector and remove the multi-media interface ECU. 4. REMOVE MULTI-DISPLAY CONTROLLER BRACKET A (a) Remove the 2 bolts and multi-display controller bracket A. Page 6301 Fuse Block: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Page 604 Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Rear Side) Components PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): COMPONENTS Page 9113 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 8236 Seat)/Removal. 2. REMOVE FRONT SEAT ASSEMBLY RH (a) for Power Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. (b) for Manual Seat: Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 3. REMOVE CENTER FRONT SEAT ASSEMBLY (a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal. 4. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 5. REMOVE CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 6. REMOVE CENTER FRONT SEAT INNER BELT ASSEMBLY (a) Remove the bolt and the center front seat inner belt. Installation SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY (for Center Seat): INSTALLATION 1. INSTALL CENTER FRONT SEAT INNER BELT ASSEMBLY (a) Install the inner belt with the nut. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) NOTICE: Do not overlap the anchor part of the seat belt and protruding part of the seat adjuster. 2. INSTALL CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 3. INSTALL CENTER SEAT BACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly Locations Ignition Switch: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Page 8495 Double Cab)/Removal 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 6. REMOVE REAR DOOR SCUFF PLATE RH (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT The procedures listed below are for the LH side. 7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH 3. INSTALL REAR DOOR SCUFF PLATE RH (a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT The procedures listed below are for the LH side. 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation 6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 8643 Television / Monitor: Service and Repair Video Terminal (for Bench Seat Type) Components AUDIO / VISUAL: VIDEO TERMINAL (for Bench Seat Type): COMPONENTS Removal AUDIO / VISUAL: VIDEO TERMINAL (for Bench Seat Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 8929 Integrated Accessory Switch Assembly: Testing and Inspection METER: DRIVE MONITOR SWITCH: INSPECTION 1. INSPECT DRIVE MONITOR SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (a) If the result is not as specified, replace the monitor switch. (b) Inspect the switch illumination. (1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 6 (ILL-). (2) Check that the light comes on. OK: LED comes on. (3) If the result is not as specified, replace the monitor switch. Up to 11/2009 Traction Control Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Locations Headlamp Alignment Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 1995 Page 18 Alarm Module: Diagrams Glass Breakage Sensor ECU Page 8684 * Some transmitter's signals stop after 1 to 2 seconds. For these types of transmitters: 1) press and hold one of the garage door opener switches, and 2) press and release (cycle) the transmitter switch every 2 seconds. Check if the transmitter code was successfully registered. * After entering the garage door opener registration mode, transmitter code registration must be completed within 90 seconds. If 90 seconds elapse, the garage door opener will enter low power mode (refer to "low power mode" below). (b) Erase transmitter codes in the garage door opener clear mode. HINT All 3 registered transmitter codes will be erased. No option exists for only erasing one transmitter code. (1) Press and hold the left and right switches of the garage door opener for 20 seconds. The LED will begin to flash at a cycle of 5.6 Hz. Releasing the switches will end clear mode. HINT * If the switches are released within 10 seconds after the transmitter codes have been erased, the garage door opener will enter registration mode. * If the switches are held for 10 seconds or more after the transmitter codes have been erased, default codes will be set to the switches of the garage door opener. Using these default codes, operation of the garage door opener can be checked using a tester. Page 8439 (a) Install the antenna ornament as shown in the illustration. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 3615 Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION 1. INSPECT AIR FUEL RATIO SENSOR (a) Disconnect the 2 sensor connectors. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the air fuel ratio sensor. (d) Connect the 2 sensor connectors. Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: HOW TO PROCEED WITH TROUBLESHOOTING HINT * Use these procedures to troubleshoot the LIN communication system. * *: Use the Techstream. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. 3. CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Using the Techstream, inspect the CAN communication function to ensure there are no malfunctions in the CAN communication system See: CAN Communication System/How to Proceed With Troubleshooting. B -- GO TO CAN COMMUNICATION SYSTEM See: CAN Communication System/How to Proceed With Troubleshooting A -- Continue to next step. 4. PROBLEM SYMPTOMS TABLE (a) Refer to the problem symptoms table See: Symptom Related Diagnostic Procedures/LIN Communication System/Problem Symptoms Table. B -- Go to step 6 A -- Continue to next step. 5. OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Terminals of ECU See: Pinout Values and Diagnostic Parameters/LIN Communication System (b) Data List / Active Test See: Scan Tool Testing and Procedures NEXT -- Continue to next step. 6. REPAIR OR REPLACE NEXT -- END How to Proceed With Troubleshooting Page 1630 Power Window Switch: Diagrams Power Window Regulator Master Switch Page 8594 Rear Vision Camera: Service and Repair Removal PARK ASSIST / MONITORING: TELEVISION CAMERA: REMOVAL 1. REMOVE TAIL GATE SERVICE HOLE COVER See: Body and Frame/Tailgate/Service and Repair/Tail Gate/Removal 2. REMOVE TELEVISION CAMERA ASSEMBLY (a) Disconnect the television camera connector. (b) Detach the 3 clamps and remove the 2 bolts and television camera. Page 5848 Disassembly Parking Brake Warning Switch: Service and Repair Disassembly PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and switch. Page 6799 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 6511 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Service and Repair Fuel Pressure Release: Service and Repair 1UR-FE FUEL: FUEL SYSTEM: PRECAUTION CAUTION: * Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. * Do not smoke or be near an open flame when working on the fuel system. * Keep gasoline away from rubber and leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures. (1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. (2) Put a container under the connecting part of the pressure line. (3) Slowly loosen the connection. (4) Disconnect the connection. (5) Plug the connection with a rubber plug. (b) Observe these precautions when removing and installing the injectors: Page 6623 Removal OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Page 69 Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab) Components DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS Page 8005 Page 9296 Page 1645 Power Window Switch: Service and Repair Front Passenger Side Power Window Switch Components WINDSHIELD / WINDOWGLASS: FRONT PASSENGER SIDE POWER WINDOW SWITCH: COMPONENTS Removal WINDSHIELD / WINDOWGLASS: FRONT PASSENGER SIDE POWER WINDOW SWITCH: REMOVAL 1. REMOVE FRONT UPPER ARMREST BASE PANEL RH Page 1852 ^ 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 6711 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 1982 Components Power Distribution Module: Service and Repair Components OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS Page 3805 Engine Temperature Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Partially immerse the sensor in water and warm up the water. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the engine coolant temperature sensor. NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. HINT If the result is as specified, do not replace the engine coolant temperature sensor. Page 1848 ^ 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 1424 Page 5286 (a) Remove the 2 bolts and heat insulator from the heat insulator bracket. 2. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY (a) Remove the 2 bolts and heat insulator bracket from the crossmember. 3. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (a) for Front Differential Side: (1) Place matchmarks on the differential and propeller shaft flange. (2) Remove the 4 nuts, 4 washers and disconnect the propeller shaft from the differential. NOTICE: Use a rope to suspend the front edge of the propeller shaft. (b) for Transfer Side: (1) Place matchmarks on the transfer and propeller shaft flanges. (2) Remove the 4 nuts and 4 washers. (c) Remove the propeller shaft from the transfer flange. Installation PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: INSTALLATION 1. INSTALL FRONT PROPELLER SHAFT Air Conditioning System (for Automatic Air Conditioning System) Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 9073 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 8676 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 6921 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Up to 11/2009 Acceleration/Deceleration Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Components Accelerator Pedal: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: COMPONENTS Page 8851 (b) Remove the 3 screws and speaker. NOTICE: Do not touch the cone part of the speaker. From 11/2009 AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 4. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 5. REMOVE REAR DOOR ARMREST COVER LH 6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door (for Double Cab)/Disassembly 7. REMOVE REAR NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 3 screws and speaker. NOTICE: Do not touch the cone part of the speaker. Up to 11/2009 AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL REAR NO. 1 SPEAKER ASSEMBLY Page 4351 Fuel Injector: Service and Repair Removal 1UR-FE FUEL: FUEL INJECTOR: REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE EGR VALVE BRACKET (a) Remove the EGR valve bracket See: Emission Control Systems/Exhaust Gas Recirculation/EGR Valve/Service and Repair/Removal. 4. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY (a) Disconnect the No. 2 fuel tube from the fuel pressure regulator See: Service Precautions. 5. DISCONNECT FUEL TUBE SUB-ASSEMBLY (a) Disconnect the fuel tube from the fuel delivery pipe RH See: Service Precautions. (b) Disconnect the fuel tube from the fuel delivery pipe LH See: Service Precautions. Engine Immobiliser System Alarm Module: Locations Engine Immobiliser System ENGINE IMMOBILISER: ENGINE IMMOBILISER SYSTEM: PARTS LOCATION Page 4614 Ignition Switch: Service and Repair Removal 1UR-FE STARTING: IGNITION SWITCH: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal. (b) for Manual Tilt and Manual Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal. (c) for Power Tilt and Power Telescopic Steering Column: Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal. 3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Disassembly 4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly 5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly 6. REMOVE IGNITION SWITCH ASSEMBLY (a) Detach the 2 claws and remove the ignition switch from the steering lock. Page 3465 CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: HOW TO PROCEED WITH TROUBLESHOOTING HINT * DTCs for the CAN communication system are as follows: U0073, U0100, U0114, U0123, U0124, U0126, U0129, U0199, U0208, U1002, U1115, B1499, and B2621 * Refer to the troubleshooting procedures of each system if DTCs regarding the CAN communication system are not output. * Before measuring the resistance, leave the vehicle for at least 1 minute and do not operate the ignition switch, any switches or doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT * Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. * *: Use the Techstream. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. 3. CHECK AND CLEAR DTC* (a) Using the Techstream, perform the ALL DTC check. NOTICE: * If a CAN communication malfunction code that informs that an ECU or sensor has a power malfunction or interior malfunction is causing a communication stop, the problem may not be in the communication line. There is a high possibility that the ECU or sensor has a signal transmission failure. Therefore, first troubleshoot any DTCs related to the ECU or sensor. * When CAN communication related connectors are disconnected with the ignition switch ON or ACC, the ECU related to the connector and ECUs of related systems will store a CAN communication DTC. NEXT -- Continue to next step. 4. CHECK INSTALLED SYSTEMS (ECU AND SENSOR) THAT USE CAN COMMUNICATION (a) Based on the vehicle equipment and specifications, confirm the systems that use CAN communication See: Initial Inspection and Diagnostic Overview/CAN Communication System/Diagnosis System. NEXT -- Continue to next step. 5. CHECK DLC3 BRANCH WIRE AND V BUS CIRCUIT MAIN WIRE (CANH - CANL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 1220 Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch Page 4590 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Locations Integrated Accessory Switch Assembly: Locations METER: METER / GAUGE SYSTEM: PARTS LOCATION Components Auxiliary Power Outlet Switch: Service and Repair Components OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS Front Power Seat Control ECU and Switch Power Seat Switch: Diagrams Front Power Seat Control ECU and Switch Page 198 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 8899 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL 1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Page 1665 Wiper Switch: Testing and Inspection WIPER AND WASHER: WIPER SWITCH: INSPECTION 1. INSPECT WIPER AND WASHER SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch assembly. (c) Check the intermittent operation. (1) Connect the voltmeter's positive (+) lead to terminal B-3 (+1) and the negative (-) lead to terminal A-2 (EW). (2) Connect the battery's positive (+) lead to terminal B-2 (+B) and the negative (-) lead to terminals A-2 (EW) and B-1 (+S). (3) Turn the wiper switch to the INT position. Page 1985 Rear Door (for CrewMax) Rear Door Panel: Service and Repair Rear Door (for CrewMax) Components ENGINE HOOD / DOOR: REAR DOOR (for CrewMax): COMPONENTS Page 6206 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL 1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL Page 5250 2. Inspect the front driveshaft (propeller shaft assembly) for a loose parts label that may be contacting other components (see Figure 1). Is the label on the front driveshaft (propeller shaft assembly) loose and contacting other components? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the cause of this condition. 3. Completely remove the front driveshaft parts label. 4. Test drive and confirm there is no abnormal noise present when in 4WD. Locations Impact Sensor: Locations SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 5130 Production Change Information This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below. Parts Information Required Tools & Equipment Inspection Procedure 1. Test drive the vehicle and confirm the noise is only present in 4WD. 2. Place the vehicle on the lift and remove the left front wheel. Page 2646 Be careful not to damage the radiator core. (g) Remove the fan pulley from the fan bracket. 7. REMOVE FAN (a) Remove the 4 nuts and fan from the fluid coupling. Page 2498 Oil Pressure Sender: Diagrams Oil Pressure Switch Page 8573 Removal PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT END PANEL LH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 3. REMOVE FRONT END PANEL RH (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 4. REMOVE FRONT BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal 5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 7. REMOVE FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 8. REMOVE FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 9. REMOVE FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 10. REMOVE FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal 11. REMOVE NO. 1 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. Page 9230 (a) Connect the connectors. (b) Attach the 2 clips to install the front upper armrest base panel. 8. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (a) Attach the 4 claws to install the bezel plug. 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 4352 6. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (a) Disconnect the No. 1 fuel pipe from the fuel delivery pipe LH See: Service Precautions. 7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY RH (a) Disconnect the No. 6 wire harness connector. (b) Remove the 2 bolts and fuel delivery pipe RH. NOTICE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward. (c) Remove the 2 delivery pipe spacers and 4 insulators from the intake manifold. 8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY LH (a) Disconnect the No. 7 wire harness connector. (b) Remove the 2 bolts and fuel delivery pipe LH. NOTICE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward. (c) Remove the 2 delivery pipe spacers and 4 insulators from the intake manifold. 9. REMOVE FUEL INJECTOR ASSEMBLY (a) Remove the fuel injector from the fuel delivery pipe, and then disconnect the injector connector. Page 7927 (b) With the steering pad removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad or steering wheel assembly with a new one: * Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. * Cracks or other damage to the connectors. * Deformation of the steering pad contact plate of the steering pad. * Deformation of the steering wheel. * There should be no interference between the steering pad and steering wheel assembly, and the clearance should be uniform all the way around when the new steering pad is installed on the steering wheel assembly. CAUTION: For removal and installation procedures of the steering pad, be sure to follow the correct procedure. Page 8494 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL 1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal 4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Page 163 Fog/Driving Lamp Relay: Testing and Inspection LIGHTING: FOG LIGHT RELAY: ON-VEHICLE INSPECTION 1. REMOVE FOG LIGHT RELAY (FOG) (a) Remove the fog light relay from the engine room relay box. 2. INSPECT FOG LIGHT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL FOG LIGHT RELAY Page 9056 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 4214 Regular Cab Fuel Pump Control Unit: Locations Regular Cab Body Page 1383 (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If the front airbag sensor has defects as mentioned below, replace it with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. 3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: * For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the front airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Side Airbag Sensor (for Double Cab) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Page 7373 HINT Release the coil spring while checking the position of the suspension support. 3. TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT (a) Tighten the nut. Torque : 25 Nm (255 kgf-cm, 18 ft-lbf) Page 6450 Power Distribution Relay: Testing and Inspection ACC Relay 1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION 1. INSPECT MAIN BODY ECU (ACC RELAY) (a) Measure the resistance of the ACC relay circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the main body ECU. Page 6648 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 9. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Using a screwdriver, detach the claw and remove the power outlet socket. HINT Tape the screwdriver tip before use. 10. REMOVE POWER OUTLET SOCKET COVER (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL POWER OUTLET SOCKET ASSEMBLY Page 4134 Page 4902 Removal A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal Page 5601 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection BRAKE CONTROL: BRAKE ACTUATOR: ON-VEHICLE INSPECTION 1. CONNECT TECHSTREAM (a) Connect the Techstream to the DLC3. (b) Start the engine and run it at idle. (c) Select the Active Test mode on the Techstream. HINT Refer to the Techstream operator's manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION (a) With the motor relay on, check the actuator motor operation noise. (b) Turn the motor relay off. (c) Depress the brake pedal and hold it for about 15 seconds. Check that the pedal does not go down any further while holding it. (d) With the motor relay on, check that the pedal could have pulsations. NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it consecutively, wait more than 20 seconds between each operation. (e) Turn the motor relay off and release the brake pedal. 3. INSPECT WHEEL OPERATION NOTICE: Never turn on a solenoid that is not described below. (a) With the brake pedal depressed, perform the following operations. (b) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) on simultaneously, and check that the pedal cannot be depressed. NOTICE: Do not keep the solenoid on for more than 10 seconds continuously. When operating it consecutively, wait more than 20 seconds between each operation. (c) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) off simultaneously, and check that the pedal can be depressed. (d) Turn the motor relay on and check that the pedal returns. NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it consecutively, wait more than 20 seconds between each operation. (e) Turn the motor relay off and release the brake pedal. (f) Using the procedure above, check the solenoids of the other wheels. HINT LEFT Front wheel LH: ABS Solenoid (SFLH), ABS Solenoid (SFLR) RIGHT Rear wheel RH: ABS Solenoid (SRRH), ABS Solenoid (SRRR) LEFT Rear wheel LH: ABS Solenoid (SRLH), ABS Solenoid (SRLR) (g) Clear the DTCs See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes. Page 6815 Page 6197 HINT Tape the screwdriver tip before use. 10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 5. INSTALL POWER OUTLET SOCKET ASSEMBLY Page 2725 (a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter protector, 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. 11. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1) (a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic converter protector and 4 No. 1 converter protector stays. 12. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter protector, 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. 13. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic converter protector and 4 No. 1 converter protector stays. Installation 1UR-FE EXHAUST: EXHAUST PIPE (for Regular Cab Standard Deck): INSTALLATION 1. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 1) (a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. (b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) Page 8499 (a) Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT The procedures listed below are for the LH side. 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 8. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL FRONT DOOR SCUFF PLATE RH (a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT The procedures listed below are for the LH side. Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Components Dimmer Switch: Service and Repair Components METER: LIGHT CONTROL RHEOSTAT: COMPONENTS Page 8872 Page 716 Removal SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT SEAT ASSEMBLY LH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 3. REMOVE RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 4. REMOVE FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 5. REMOVE LEG SUPPORT ADJUSTMENT SWITCH (w/ Leg Support Adjustment Switch) (a) Detach the 2 wire harness clamps and remove the 2 screws and switch. (b) Disconnect the switch connector. 6. REMOVE FRONT POWER SEAT SWITCH LH Page 2933 Engine Temperature Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the sensor. (b) Using a 19 mm ball joint lock nut wrench, install the sensor. Torque : 20 Nm (200 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench See: Service Precautions (c) Connect the sensor connector. 2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing and Inspection 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 6283 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 8587 Parking Assist Switch: Service and Repair Removal PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE DRIVE MONITOR SWITCH (a) Detach the 2 claws and remove the monitor switch. Page 4005 Air Injection Control Valve: Diagrams Page 2562 Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the Techstream to the DLC3. (b) Start the engine and turn the tester ON. (c) Warm up the engine. (d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear (Bank 1) or Control the VVT Linear (Bank 2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2). (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK: (f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear. HINT * Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of bank 1 (Control range: Between -128 to 127%). * Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves of bank 2 (Control range: Between -128 to 127%). * Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range: ON/OFF). * Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range: ON/OFF). * Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of bank 1 (Control range: Between -128 to 127%). * Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of bank 2 (Control range: Between -128 to 127%). Page 1979 Fuse: Application and ID Fuse Layout and Amperage Ratings Fuse Block Location - Engine Compartment Fuse Location - Engine Compartment Page 7052 (b) * for 5 leaf spring 6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Install the camber-caster-kingpin gauge or place the front wheels on the center of the wheel alignment tester. Page 1497 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Locations Turn Signal Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 5656 (e) Attach the 3 clips (labeled F). NOTICE: * When installing the clips, do not twist the wire harness. * When installing the clips, securely insert them as shown in the illustration. (f) Connect the speed sensor connector (labeled G). NOTICE: Securely connect the connector. 7. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 2831 Engine Control Module: Programming and Relearning 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The Techstream is required to register the VIN. 1. DESCRIPTION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT This registration section consists of two parts: Read VIN and Write VIN. (a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read in order to confirm that the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the same. (b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM by following this procedure. 2. READ VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read. 3. WRITE VIN (a) Confirm the vehicle VIN. (b) Connect the Techstream to the DLC3. (c) Turn the ignition switch to ON. (d) Turn the Techstream on. (e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write. Page 1682 for Double Cab of Long Deck Page 2696 HINT The direction of hose clamp is indicated in the illustration. 5. CONNECT NO. 8 WATER BY-PASS HOSE (a) Connect the water by-pass hose. HINT The direction of hose clamp is indicated in the illustration. 6. INSTALL NO. 1 WATER BY-PASS HOSE (a) Install the water by-pass hose. HINT The direction of hose clamp is indicated in the illustration. 7. INSTALL WATER BY-PASS PIPE (w/ Oil Cooler) (a) Connect the 4 water hoses. HINT Connect each hose so that the direction of each hose clamp is as indicated in the illustration. (b) Install the water by-pass hose with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 4303 ^ 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 5269 Page 5415 Four Wheel Drive Selector Switch: Service and Repair Installation JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION 1. INSTALL 4WD CONTROL SWITCH (a) Attach the 3 claws to install the switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 851 Yaw Rate Sensor: Testing and Inspection BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION 1. CHECK YAW RATE SENSOR (a) Check the yaw rate sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 3717 Engine Control Module: Diagrams Page 7359 Suspension Strut / Shock Absorber: Testing and Inspection Rear Shock Absorber SUSPENSION: REAR SHOCK ABSORBER: INSPECTION 1. INSPECT REAR SHOCK ABSORBER ASSEMBLY LH (a) Compress and extend the shock absorber rod 4 times or more. Check that there is no abnormal resistance or unusual sound during the operation. If there is any abnormality, replace the shock absorber assembly with a new one. NOTICE: * When disposing of the shock absorber, see DISPOSAL See: Service and Repair/Removal and Replacement/Rear Shock Absorber/Disposal * Do not hold the rear shock absorber by the dust cover, as the dust cover will come off. Page 1468 Page 9382 Parts Information Repair Procedure 1. Test-drive the vehicle and confirm the condition. NOTE Repeat remaining steps for both No.3 cab mounts. 2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is necessary to allow the cab to be raised to remove the No.3 mount. The cab mounts in the front are only loosened to allow the technician to raise the cab to install the rear cab mounts. Not necessary to change. Components Air Injection Pump: Service and Repair Components 1UR-FE EMISSION CONTROL: AIR PUMP: COMPONENTS Page 7938 CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT The airbag is deployed as the LED of SST activation switch comes on. (h) Dispose of the front seat side airbag. CAUTION: * The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag. * Do not apply water to a front seat side airbag with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the front seat side airbag from the tire. (2) Place the front seat side airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Curtain Shield Airbag Assembly SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: DISPOSAL HINT When scrapping a vehicle equipped with the SRS or disposing of the curtain shield airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a curtain shield airbag that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the curtain shield airbag. * The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag. * Do not apply water to a curtain shield airbag with a deployed airbag. * Always wash your hands with water after completing the operation. * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 4624 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Page 2256 12. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 13. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 14. CHECK PARKING BRAKE INSTALLATION See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 15. INSTALL REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and Repair/Removal and Replacement/Rear Brake/Installation 16. ADJUST PARKING BRAKE SHOE CLEARANCE See: Brakes and Traction Control/Parking Brake System/Adjustments 17. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction Control/Parking Brake System/Service and Repair/Reassembly 18. INSTALL REAR WHEEL LH for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 19. CHECK PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake System/Adjustments 20. ADJUST PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake System/Adjustments A760F Automatic Transmission System Control Module: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 8065 Impact Sensor: Testing and Inspection Side Airbag Sensor (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 1882 (a) Hook the engine under cover to the vehicle body as shown in the illustration. (b) Install the 3 screws and 5 bolts. for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf) Page 8368 Service and Repair Fuel Pressure Release: Service and Repair 1UR-FE FUEL: FUEL SYSTEM: PRECAUTION CAUTION: * Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. * Do not smoke or be near an open flame when working on the fuel system. * Keep gasoline away from rubber and leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures. (1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. (2) Put a container under the connecting part of the pressure line. (3) Slowly loosen the connection. (4) Disconnect the connection. (5) Plug the connection with a rubber plug. (b) Observe these precautions when removing and installing the injectors: Diagram Information and Instructions Compressor HVAC: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 3002 Variable Valve Timing Actuator Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION 1. INSTALL VVT SENSOR (a) Install the 4 sensors with the 4 bolts. Testing and Inspection Condenser HVAC: Testing and Inspection AIR CONDITIONING: CONDENSER: ON-VEHICLE INSPECTION 1. INSPECT COOLER CONDENSER ASSEMBLY (a) If the fins of the cooler condenser are dirty, clean them with water. Dry the fins with compressed air. NOTICE: Do not damage the fins of the condenser. (b) If a fin of the cooler condenser is bent, straighten it using a screwdriver or pliers. 2. CHECK CONDENSER FOR LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check the pipe joints for gas leakage. (b) If gas leakage is detected in a joint, check the torque of the joint. Components EGR Valve: Service and Repair Components 1UR-FE EMISSION CONTROL: EGR VALVE: COMPONENTS Page 3581 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Removal and Replacement Compressor HVAC: Removal and Replacement Components AIR CONDITIONING: COMPRESSOR (for 1UR-FE): COMPONENTS Page 5943 Components Tire Pressure Module: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS Airbag System Seat Occupant Classification Module - Air Bag: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 2080 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Page 7560 Ambient Temperature Sensor / Switch HVAC: Diagrams Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Specifications Exhaust Manifold: Specifications EXHAUST MANIFOLD SUB-ASSEMBLY RH Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration. For nut A - Torque................................................................................................................................ ......................................10 Nm (102 kgf-cm, 7 ft-lbf) Except nut A - Torque........................................................................................................................... ....................................21 Nm (214 kgf-cm, 15 ft-lbf) EXHAUST MANIFOLD SUB-ASSEMBLY LH Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration. For nut A - Torque................................................................................................................................ ......................................10 Nm (102 kgf-cm, 7 ft-lbf) Except nut A - Torque........................................................................................................................... ....................................21 Nm (214 kgf-cm, 15 ft-lbf) Page 5311 Flex Plate: Testing and Inspection A760F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE: INSPECTION 1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the 1-way clutch. (1) Install SST to the inner race of the 1-way clutch. SST : 09350-32014 09351-32020 (2) Press on the serrations of the stator with a finger and rotate it. Check that the stator rotates smoothly when turned clockwise and locks when turned counterclockwise. If the results are not as specified, clean the converter and recheck the 1-way clutch. If the results still are not as specified, replace the torque converter clutch assembly. (b) Determine the condition of the torque converter clutch. (1) Check that the following conditions are met: * During the stall test or when the shift lever is in N, metallic sounds are not emitted from the torque converter clutch. * The 1-way clutch turns in one direction and locks in the other direction. * The amount of powder in the ATF is not more than the sample shown in the illustration. (2) If the results are not as specified, replace the torque converter clutch assembly. HINT The sample illustration shows approximately 0.25 liters (0.26 US qts, 0.22 Imp. qts) of ATF taken from a removed torque converter clutch. Page 2766 ^ 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 7147 Tire Pressure Sensor: Diagrams Page 6148 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 7498 Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: * No further tightening is required once the nut is tightened with the specified torque. * Check that there is no foreign matter on the washer and nut. * Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve, washer and nut. Failing to do so may result in improper installation. (d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main body of the tire pressure warning valve and transmitter in the shaded area as shown in the illustration. NOTICE: * If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will interfere with the tire pressure warning valve and transmitter, and may cause damage to it. * If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the tire pressure warning valve and transmitter. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is not clamped by the bead. (f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: Diagrams Variable Valve Timing Actuator Position Sensor: Diagrams Drivetrian - Rear End Howling/Growling Noises Axle Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 4672 Control Module: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Diagram Information and Instructions Relay Box: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 8819 4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE FRONT DOOR ARMREST COVER LH 6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 4 screws and speaker. NOTICE: Do not touch the cone part of the speaker. 9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) (a) Remove the 3 screws and speaker with bracket. (b) Detach the 3 claws and remove the speaker from the bracket. NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. Page 3729 Page 3462 Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (POWER STEERING ECU BRANCH WIRE) (a) Disconnect the J101 power steering ECU connector. Page 5353 Transmission Speed Sensor: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION 1. INSTALL SPEED SENSOR SP2 (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. 2. INSTALL SPEED SENSOR NT (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. Page 3003 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 1585 Transmission Speed Sensor: Testing and Inspection A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION 1. INSPECT SPEED SENSOR NT (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. 2. INSPECT SPEED SENSOR SP2 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the sensor. Page 1761 Spark Plug: Service and Repair Removal 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the MAF meter connector and clamp. (b) Disconnect the ventilation hose and vacuum hose. (c) Loosen the hose clamp. (d) Remove the 2 bolts and air cleaner. 3. REMOVE IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Disconnect the 3 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Remove the 4 bolts and 4 ignition coils. (b) for Bank 2: (1) Disconnect the 2 wire harness clamps. (2) Disconnect the 4 ignition coil connectors. (3) Disconnect the engine wire harness clamp. Page 2407 (b) Disconnect the ground wire from the cylinder block. 11. REMOVE OIL FILTER BRACKET (a) Remove the 2 bolts, 2 nuts and filter bracket. (b) Remove the 2 O-rings. 12. REMOVE OIL COOLER ASSEMBLY (a) Remove the 5 nuts and oil cooler from the oil filter bracket. (b) Remove the 2 O-rings. 13. REMOVE OIL COOLER SPACER (a) Remove the bolt and oil cooler spacer from the oil filter bracket. Components Camshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS Page 4174 Page 2845 Oxygen Sensor Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (A/F) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the A/F fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the A/F fuse. (b) Measure the resistance of the A/F sensor heater relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 4549 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY (a) Connect the 3 connectors. (b) Install the integration relay to the engine room relay block. (c) Install the engine room relay block cover. Page 4090 EGR Valve: Service and Repair Removal 1UR-FE EMISSION CONTROL: EGR VALVE: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 4. DISCONNECT NO. 12 WATER BY-PASS HOSE (a) Disconnect the No. 12 water by-pass hose. 5. DISCONNECT NO. 13 WATER BY-PASS HOSE (a) Disconnect the No. 13 water by-pass hose. 6. REMOVE EGR VALVE ASSEMBLY (a) Disconnect the 3 clamps and connector. (b) Remove the 4 nuts. (c) Remove the 2 bolts and EGR valve. Page 3743 Engine Control Module: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION 1. INSTALL GASKET (a) Clean the ECM seal's surface with non-residue solvent. (b) Attach a new gasket to the ECM. 2. INSTALL ECM (a) Install the ECM with the 4 bolts. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) NOTICE: * Make sure the gasket is not folded or caught on any area on the surrounding part. * Make sure there is no foreign matter caught between the gasket and surrounding part. * Do not damage the gasket. (b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors. NOTICE: * Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do this may cause the lock lever and terminals to break. * Do not twist the wire harness when connecting the ECM connectors. (c) Connect the wire harness clamp. 3. CONNECT CONNECTOR HOLDER BLOCK (a) Connect the connector holder block with the 3 bolts. Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf) Page 8097 Page 9132 Trailer Connector: Connector Views Page 2452 Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Components Drive Belt: Service and Repair Components 1UR-FE ENGINE MECHANICAL: DRIVE BELT: COMPONENTS Components Tire Pressure Sensor: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS Component Tests and General Diagnostics Steering Angle Sensor: Component Tests and General Diagnostics BRAKE CONTROL: STEERING ANGLE SENSOR: INSPECTION 1. CHECK STEERING ANGLE SENSOR (a) Check the steering angle sensor. Under any of the following conditions, replace the sensor with a new one: * The surface of the sensor is cracked, dented, or chipped. * The connector is scratched, cracked, or damaged. * The sensor has been dropped. Page 8656 Page 838 Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamp, do not twist the wire harness. * Make sure the clamp's rotation stopper touches the installation position. (d) Attach the 3 clips (labeled E). NOTICE: * When installing the clips, do not twist the wire harness. * When installing the clips, securely insert them as shown in the illustration. (e) Connect the speed sensor connector (labeled F). NOTICE: Securely connect the connector. 4. INSTALL FRONT SKID CONTROL SENSOR CLAMP RH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle. 5. INSTALL FRONT SPEED SENSOR RH (a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E). Page 8231 Seat Belt: Removal and Replacement Components SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: COMPONENTS Page 1488 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 7668 Compressor HVAC: Overhaul Disassembly AIR CONDITIONING: COMPRESSOR (for 1UR-FE): DISASSEMBLY 1. REMOVE COOLER BRACKET (a) Detach the clamp. (b) Remove the screw and the cooler bracket. 2. REMOVE MAGNET CLUTCH ASSEMBLY (a) Clamp the cooler compressor in a vise. (b) Using SST, hold the magnet clutch hub. SST : 09985-00270 (c) Remove the bolt, magnet clutch hub and magnet clutch washer(s). HINT There is no set number of magnet clutch washers since they are used for adjusting. (d) Using a snap ring expander, remove the snap ring and the magnet clutch rotor. NOTICE: Do not damage the seal cover of the bearing when removing the snap ring. (e) Disconnect the connector. (f) Using a snap ring expander, remove the snap ring and magnet clutch stator. Page 7222 Steering Control Module: Diagrams Page 2721 Torque : 54 Nm (554 kgf-cm, 40 ft-lbf) (c) Connect the air fuel ratio sensor connector. 10. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Installation 11. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Installation 12. INSTALL CENTER EXHAUST PIPE ASSEMBLY (a) Connect the center exhaust pipe to the 3 exhaust pipe supports. (b) Install 2 new gaskets to the front exhaust pipes. (c) Install the center exhaust pipe with the 4 bolts. Torque : 48 Nm (489 kgf-cm, 35 ft-lbf) 13. INSTALL TAILPIPE ASSEMBLY (a) Connect the tailpipe to the exhaust pipe support. (b) Install a new gasket to the center exhaust pipe. (c) Connect the tailpipe to the center exhaust pipe. (d) Attach a new clamp to the tailpipe and center exhaust pipe. Then install the bolt to the clamp. Torque : 32 Nm (326 kgf-cm, 24 ft-lbf) HINT Install the clamp within the angle range shown in the illustration. 14. INSPECT FOR EXHAUST GAS LEAK See: Exhaust Manifold/Service and Repair/Installation Page 4989 (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. 9. INSPECT SHIFT SOLENOID VALVE SLU (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. Locations Transmission Mode Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 4173 Page 8413 Seat Position Sensor: Service and Repair Removal SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY LH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Removal. 2. REMOVE SEAT POSITION SENSOR (a) Using a T30 "TORX" socket wrench, remove the screw and seat position sensor with sensor protector. (b) Disconnect the connector. (c) Remove the seat slide position sensor protector from the seat position sensor. Engine - Controls - Non-Linear Acceleration From A Stop Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 3370 "Case2" 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 Regular Cab Fuel Pump Control Unit: Locations Regular Cab Body Specifications Spark Plug: Specifications SPARK PLUG Using a 16 mm plug wrench, install the 8 spark plugs. Torque.................................................................................................................................................. .....................................21 Nm (214 kgf-cm, 15 ft-lbf) GAP Page 1750 * Never reuse the O-ring. * When placing a new O-ring on the injector, do not damage it. * Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and intake manifold as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type). (1) for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration. (2) for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector. Page 6729 Page 7435 Tire Pressure Monitor Receiver / Transponder: Diagrams Page 8744 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 8825 Page 6062 * In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. * Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. * The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1. DTC CHECK NEXT -- Continue to next step. 2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT -- Continue to next step. 3. SYMPTOM CONFIRMATION B -- Go to step 5 A -- Continue to next step. 4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT -- Continue to next step. 5. DTC CHECK B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step. 6. SYMPTOM CONFIRMATION Diagrams Accessory Control Display: Diagrams Page 5845 (1) Keep the vehicle stationary on a level surface for 1 second or more. HINT * The zero point calibration is performed only once after the system enters test mode. * Calibration cannot be performed again until the stored data is cleared once. (2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased. (3) Turn the ignition switch off. 6. PERFORM INITIALIZATION OF STEERING ANGLE SENSOR NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will become misaligned. (a) Check that the steering wheel is in the centered position. (b) Disconnect the negative battery terminal for more than 2 seconds. NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. (c) Reconnect the negative battery terminal. Page 9127 Page 2424 (g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap. NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap. (h) Install the oil filter drain plug. Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Be careful that the O-ring does not get caught between any surrounding parts. 5. ADD ENGINE OIL (a) Add fresh oil. Standard Oil Grade (for USA): Standard Oil Grade (for Canada): Standard Oil Capacity: (b) Install the oil filler cap. 6. INSPECT FOR OIL LEAK (a) Start the engine. Make sure that there are no oil leaks from the area that was worked on. 7. CHECK ENGINE OIL LEVEL See: Testing and Inspection 8. INSTALL NO. 1 ENGINE UNDER COVER Page 3744 (b) Install the connector holder block cover. 4. INSTALL AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and Repair/Installation 5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 3300 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 54 6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 245 Power Distribution Module: Service and Repair Installation OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION 1. INSTALL VOLTAGE INVERTER ASSEMBLY (a) Connect the voltage inverter connector. (b) Install the voltage inverter with the 2 bolts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 7960 (1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the disc wheel which the steering pad is tied to. (3) Press SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT The airbag is deployed as the LED of SST activation switch comes on. (g) Dispose of the steering pad. CAUTION: * The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a steering pad with a deployed airbag. * Do not apply water to a steering pad with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the steering pad from the disc wheel. (2) Place the steering pad in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Curtain Shield Airbag Assembly (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax): DISPOSAL Page 8270 (a) Remove the bolt and seat belt. 3. DISCONNECT REAR SEAT INNER BELT ASSEMBLY (a) Remove the bolt and disconnect the inner belt. 4. REMOVE REAR SEAT ASSEMBLY LH (a) Remove the 4 bolts and seat. 5. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER LH See: Body and Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly (for Crewmax LH Side)/Disassembly Page 1963 * Low pedal or spongy pedal. * Brake pedal is depressed firmly but braking is insufficient. (c) Check and adjust brake fluid level in reservoir See: Fluids/Brake Fluid/Testing and Inspection. 2. BLEED BRAKE SYSTEM (a) Bleed brake master cylinder HINT If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder. (1) Remove the brake master cylinder reservoir filler cap assembly. (2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir. Brake fluid: SAE J1703 or FMVSS No. 116 DOT3 (3) Using a union nut wrench, disconnect the 2 brake lines from the master cylinder. (4) Slowly depress and hold the brake pedal. (5) Block the outer holes with your fingers, and release the pedal. (6) Repeat the 2 previous steps 3 or 4 times. (7) Using a union nut wrench, connect the 2 brake lines to the master cylinder. without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf) with union nut wrench - Torque : 18 Nm (185 kgf-cm, 13 ft-lbf) * Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). * This torque value is effective when union nut wrench is parallel to the torque wrench. (b) Bleed brake line (1) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH. (2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (3) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (4) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (5) Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (6) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for RH. (7) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH. Page 753 Sunroof / Moonroof Switch: Testing and Inspection SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): INSPECTION 1. INSPECT SLIDING ROOF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the switch. Page 8030 Air Bag Deactivation Switch: Testing and Inspection Curtain Shield Airbag Cutoff Switch SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: INSPECTION 1. INSPECT CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 3534 Standard resistance: NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- REPLACE NO. 2 JUNCTION CONNECTOR 8. CONNECT CONNECTOR (a) Reconnect the J113 No. 2 junction connector connector. NEXT -- Continue to next step. 9. CHECK FOR OPEN IN CAN BUS MAIN WIRE (ECM - NO. 2 JUNCTION CONNECTOR) (a) Disconnect the A24 ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Result E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (ECM - NO. 2 JUNCTION CONNECTOR) Page 1427 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 6. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly 8. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched Page 7173 6. INSTALL FRONT AXLE HUB SUB-ASSEMBLY LH (a) Install the front axle hub See: Suspension/Wheel Hub/Service and Repair/Removal and Replacement/Installation. 7. CONNECT FRONT SPEED SENSOR LH (a) Connect the front speed sensor to the steering knuckle with the bolt. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) (b) Attach the clip to the steering knuckle. 8. INSTALL FRONT WHEEL for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf) for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 12. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair. 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 7586 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 3210 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 4060 Canister Purge Solenoid: Diagrams Page 856 Yaw Rate Sensor: Service and Repair Installation BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION 1. INSTALL YAW RATE SENSOR (a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of the sensor bracket. (b) Install the yaw rate sensor with the 2 nuts (labeled C). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * Make sure that the sensor is oriented correctly. * If the sensor is dropped, replace it. * Securely connect the connector. * When installing the sensor, make sure to avoid impacts to the sensor. 2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation 3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning. 6. CHECK YAW RATE SENSOR SIGNAL (a) Check the yaw rate sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Test Mode Procedure. Page 4059 Canister Purge Solenoid: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 7878 Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 6740 J/B No.3 - Instrument Panel Right Page 2542 Parts Information Required Tools & Equipment Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE). TSB Overview 1. Confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Diagnose the Oil Control Valves (OCVs) for proper operation. 3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair Manual. Diagnostic Procedure 1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM. 2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that the valve is stuck. 3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-) battery voltage to terminal 2. Valve should move quickly when voltage is applied. If NOT valve should be replaced. 4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using Tech stream. Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2) 5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair procedure below. Repair Procedure 1. Replace both intake VVTi gears. Page 21 Components Refrigerant Pressure Sensor / Switch: Service and Repair Components AIR CONDITIONING: PRESSURE SWITCH: COMPONENTS Page 4676 Control Module: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. HINT Use the same procedures described for the LH side. 3. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. HINT Use the same procedures described for the LH side. 4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE 4WD CONTROL ECU (a) Disconnect the 2 ECU connectors. (b) Remove the bolt and ECU. Page 4560 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Page 3481 INSPECTION PROCEDURE HINT * Perform the following inspection for the ECUs (sensors) which are not displayed on the Techstream. If a malfunction cannot be identified, perform the following inspections for the ECUs (sensors) connected to the CAN communication system. * Do not remove the combination meter and ECM, as they are the end parts of the circuit. If removed, CAN communication will not be possible. * The open circuit confirmation of the combination meter, ECM and main wire is performed in the CHECK CAN BUS LINE procedure of "HOW TO PROCEED WITH TROUBLESHOOTING". This inspection only has procedures for checking for an open circuit on one side of the CAN branch wire. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. Locations Fuel Pump Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 241 Power Distribution Module: Diagrams Voltage Inverter Television Display Television / Monitor: Service and Repair Television Display Components AUDIO / VISUAL: TELEVISION DISPLAY: COMPONENTS Removal AUDIO / VISUAL: TELEVISION DISPLAY: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 3896 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Page 7237 Power Steering Pressure Switch: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: INSTALLATION 1. INSTALL POWER STEERING OIL PRESSURE SWITCH (a) Install a new O-ring to the power steering oil pressure switch. (b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch. NOTICE: * When reusing the power steering oil pressure switch, inspect the O-ring. * If the O-ring has scratches or cuts, replace the power steering oil pressure switch. (c) Using SST, install the power steering oil pressure switch. SST : 09922-10010 without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf) HINT * Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification See: Service Precautions * Make sure SST and the torque wrench are connected in a straight line. (d) Connect the oil pressure switch connector. 2. INSTALL FAN AND GENERATOR V BELT (a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation. 3. ADD POWER STEERING FLUID 4. BLEED POWER STEERING FLUID See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 5. INSPECT FOR POWER STEERING FLUID LEAK 6. CHECK FLUID LEVEL See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection 7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Installation 8. INSTALL FRONT WHEEL See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Shock Absorber/Installation Page 8372 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Locations Headlamp Dimmer Relay: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 836 (c) Disconnect the connector (labeled D). (d) Remove the connector (labeled D) from the skid control sensor clamp (labeled H). (e) Remove the 2 bolts (labeled E) and 2 harness clamps (labeled F). (f) Remove the bolt (labeled G) and skid control sensor clamp (labeled H). 7. REMOVE FRONT SPEED SENSOR RH (a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the knuckle. 8. REMOVE FRONT SKID CONTROL SENSOR CLAMP RH (a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle. Installation BRAKE CONTROL: FRONT SPEED SENSOR: INSTALLATION 1. INSTALL FRONT SKID CONTROL SENSOR CLAMP LH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle. Page 3035 Throttle Position Sensor: Diagrams Page 5678 (8) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (9) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (10)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (11)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (12)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (c) Bleed VSC actuator assembly NOTICE: After bleeding the air from the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding of the brake actuator with the Techstream by following the procedure below. (1) Depress the brake pedal more than 20 times with the engine off. (2) Connect the Techstream to the DLC3, and turn the ignition switch on. NOTICE: Do not start the engine. (3) Select AIR BLEEDING on the Techstream. HINT Refer to the Techstream operator's manual for further details. (4) Bleed the air out of the suction line. NOTICE: * Perform the bleeding at the right front wheel and right rear wheel. * Bleed the air by following the steps displayed on the Techstream. (5) 1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel. 2. Loosen the bleeder plug. 3. Operate the brake actuator to bleed the air using the Techstream. HINT This operation stops automatically after 4 seconds. NOTICE: Release the brake pedal at this time. (6) 4. Check if the operation has stopped by referring to the Techstream display. 5. Temporarily tighten the bleeder plug. 6. Repeat the 4 previous steps until all in the fluid is completely bled out. 7. Tighten the bleeder plug. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (7) 8. Repeat all of the above procedures for the other wheel to bleed the air out of the suction line. (8) Bleed the air out of the pressure reduction line. NOTICE: * Perform the bleeding at the 4 wheels. * Bleed the air by following the steps displayed on the Techstream. (9) 1. Connect a vinyl tube to one of the bleeder plugs. Page 7733 (a) Remove the filter. 6. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (a) Remove the screw and duct. 7. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Remove the 2 screws and amplifier. 8. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY (a) Remove the 3 screws and motor. 9. REMOVE AIR DUCT (a) Remove the 2 screws and duct. Page 9077 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Locations Tire Pressure Monitor Receiver / Transponder: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 9176 Removal EXTERIOR: SIDE STEP: REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. REMOVE SIDE STEP ASSEMBLY (a) Remove the 8 bolts and side step. 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 214 Headlamp Relay: Testing and Inspection LIGHTING: HEADLIGHT RELAY: ON-VEHICLE INSPECTION 1. REMOVE HEADLIGHT RELAY (HEAD) (a) Remove the headlight relay from the engine room relay box. 2. INSPECT HEADLIGHT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL HEADLIGHT RELAY Air Conditioning System (for Automatic Air Conditioning System) Compressor Clutch Relay: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 8666 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Diagrams Trailer Brake Control Module: Diagrams Page 3105 Knock Sensor: Diagrams Page 2110 (a) Disconnect the ECM connector. (b) Disconnect the combination meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 5. CHECK THAT MIL IS ILLUMINATED (a) Check if the MIL is illuminated when the ignition switch is turned to ON. OK: MIL should be illuminated. NG -- CHECK THAT ENGINE STARTS OK -- END 6. CHECK THAT ENGINE STARTS (a) Turn the ignition switch to ON. (b) Start the engine. Result HINT *: The Techstream cannot communicate with the ECM. Page 4259 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 8621 Auxiliary Input / Output Jack: Diagrams Video Terminal Page 6121 6. REMOVE PLANETARY GEAR (a) Remove the 3 planetary gears. Reassembly 1UR-FE STARTING: STARTER (for 2.0 kW Type): REASSEMBLY 1. INSTALL PLANETARY GEAR (a) Apply high temperature grease to the planetary gears and pins of the starter center bearing clutch, as shown in the illustration. (b) Install the 3 planetary gears. 2. INSTALL STARTER ARMATURE PLATE (a) Install the plate to the starter center bearing clutch. NOTICE: Check that the protrusion of the starter armature plate fits in the notch of the starter center bearing clutch. 3. INSTALL STARTER ARMATURE ASSEMBLY (a) Install the starter armature to the starter center bearing clutch. 4. INSTALL STARTER YOKE ASSEMBLY (a) Align the protrusion of the starter center bearing clutch with the notch of the starter yoke, and install the starter yoke. Page 6935 Engine Room R/B, J/B - Engine Compartment Left Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity (drain and refill-Reference) With filter .............................................................................................................................................. ............................................................. 7.9 qt (7.5L) Without filter ...................................................... ................................................................................................................................................ 7.4 qt (7.1L) Page 4852 Shift Interlock Control Module: Diagrams Specifications Timing Chain Tensioner: Specifications NO. 1 CHAIN TENSIONER ASSEMBLY LH Install a new gasket and the chain tensioner with the 2 bolts. Torque.................................................................................................................................................. .......................................10 Nm (102 kgf-cm, 7 ft-lbf) NO. 1 CHAIN TENSIONER ASSEMBLY RH Install the chain tensioner with the 2 bolts. Torque.................................................................................................................................................. .......................................10 Nm (102 kgf-cm, 7 ft-lbf) NO. 2 CHAIN TENSIONER ASSEMBLY Install the chain tensioner with the 2 bolts. Torque.................................................................................................................................................. .......................................10 Nm (102 kgf-cm, 7 ft-lbf) NO. 3 CHAIN TENSIONER ASSEMBLY Install the chain tensioner with the 2 bolts. Torque.................................................................................................................................................. .......................................10 Nm (102 kgf-cm, 7 ft-lbf) Page 1691 for CrewMax of standard deck Page 1372 Page 1891 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 1549 Tire Pressure Sensor: Diagrams Page 3716 Engine Control Module: Locations Engine Compartment Page 1867 (3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. (4) Pinch the connector and disconnect the connector and pipe. (5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out. NOTICE: Do not use any tools. (6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. (7) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag. (e) Observe these precautions when connecting the fuel tube connector (for Quick Type). (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe. (3) After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected. Page 8017 Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 6. REMOVE CONSOLE BOX CARPET 7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the holder (with connectors). (b) Remove the 3 bolts and airbag sensor. Installation SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the airbag sensor with the 3 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) NOTICE: * If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the center airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the center airbag sensor. Page 3347 Engine Temperature Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement 2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and Repair 4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm ball joint lock nut wrench, remove the sensor. (c) Remove the gasket from the sensor. Page 1632 Power Window Switch: Diagrams Rear Power Window Switch Page 6714 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 3656 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 8642 2. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE VIDEO TERMINAL (a) Detach the clamp from the end panel. (b) Detach the 4 claws and remove the video terminal. Installation AUDIO / VISUAL: VIDEO TERMINAL (for Separate Seat Type): INSTALLATION 1. INSTALL VIDEO TERMINAL (a) Attach the 4 claws to install the video terminal. (b) Attach the clamp to the end panel. 2. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 6265 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 2667 4. CONNECT OUTLET RADIATOR HOSE See: Thermostat/Service and Repair/Installation 5. INSTALL FAN SHROUD (a) Install the fan shroud See: Radiator Cooling Fan/Service and Repair/Installation. Page 4164 Page 6982 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Components Power Steering Pressure Switch: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: COMPONENTS Page 7368 3. REMOVE REAR SHOCK ABSORBER ASSEMBLY LH (a) Support the rear axle housing with a jack using a wooden block to avoid damage. (b) Remove the bolt and nut on the lower side of the shock absorber. (c) While holding the piston rod, remove the nut, retainer, No. 1 cushion and shock absorber. (d) Remove the 2 retainers and No. 3 cushion from the shock absorber. Installation SUSPENSION: REAR SHOCK ABSORBER: INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. TEMPORARILY INSTALL REAR SHOCK ABSORBER ASSEMBLY LH (a) Install the 2 retainers and No. 3 cushion to the shock absorber. Page 694 Power Mirror Switch: Service and Repair Installation MIRROR: OUTER MIRROR SWITCH: INSTALLATION 1. INSTALL OUTER MIRROR SWITCH ASSEMBLY (a) Attach the 2 claws to install the outer mirror switch. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation Page 498 Steering Column Control Module: Service and Repair Installation STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): INSTALLATION 1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU (a) Install the ECU with the 2 screws. Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf) (b) Connect the 2 ECU connectors. 2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Installation 6. INSTALL LOWER STEERING COLUMN COVER (a) Attach the 2 claws to install the steering column lower cover. 7. INSTALL UPPER STEERING COLUMN COVER Page 2148 Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Install the receiver with the bolt. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the receiver connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 4165 Page 6326 MJ1-NP1 Page 6034 Page 7968 (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Remove the front seat side airbag See: Removal and Replacement/Front Seat Side Airbag Assembly (for Fold Down Seat Type)/Removal. (c) Using a service-purpose wire harness for the vehicle, tie down the front seat side airbag to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.00193 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2). HINT To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Install the 2 nuts to the front seat side airbag. (2) Wind the wire harness around the stud bolts of the front seat side airbag as shown in the illustration. (3) Position the front seat side airbag inside the tire. Page 5067 10. INSTALL FRONT DIFFERENTIAL CASE BEARING HINT When replacing the 2 differential case bearings, fit the thinnest washer to each bearing. When reusing the bearings, fit a washer of the same thickness as the one removed to each bearing. (a) Install a new plate washer to the side bearing retainer. (b) Using SST and a press, install the bearing (outer race) onto the differential case bearing retainer. SST : 09950-60020 09951-00890 SST : 09950-70010 09951-07150 (c) Install a new plate washer onto the differential carrier. (d) Using SST and a press, press in the bearing (outer race) onto the differential carrier assembly. SST : 09950-60020 09951-00890 SST : 09950-70010 09951-07150 11. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING (a) Using SST, install the bearing (outer race). SST : 09950-60020 Locations Manifold Pressure/Vacuum Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6742 J/B No.5 - Instrument Panel Center Page 6201 7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Detach the 2 claws and remove the power outlet socket cover. Installation OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION 1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab) (a) Attach the 2 claws to install the power outlet socket cover. 2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab) (a) Attach the claw to install the power outlet socket. 3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL POWER OUTLET SOCKET COVER (a) Attach the 2 claws to install the power outlet socket cover. 5. INSTALL POWER OUTLET SOCKET ASSEMBLY Door Control Receiver (for CrewMax) Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax) Components DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS Removal DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal Components Parking Assist Switch: Service and Repair Components PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: COMPONENTS Page 4570 Crankshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR (a) Install the sensor protector with the 2 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) Page 8049 Locations Hood Sensor/Switch (For Alarm): Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 190 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 6132 Accessory Relay: Diagrams Page 6907 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. Page 7981 (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt Components Transmission Cooler: Service and Repair Components A760F AUTOMATIC TRANSMISSION: OIL COOLER: COMPONENTS Page 1505 Ignition Switch: Service and Repair Installation 1UR-FE STARTING: IGNITION SWITCH: INSTALLATION 1. INSTALL IGNITION SWITCH ASSEMBLY (a) Attach the 2 claws to install the ignition switch to the steering lock. 2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt)/Reassembly 3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly 4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly 5. INSTALL STEERING COLUMN ASSEMBLY (a) for Manual Tilt: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation. (b) for Manual Tilt and Manual Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation. (c) for Power Tilt and Power Telescopic Steering Column: Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation. 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Locations Engine Temperature Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 8549 Central Control Module: Service and Repair Installation AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: INSTALLATION 1. INSTALL MULTI-DISPLAY CONTROLLER BRACKET A (a) Install the multi-display controller bracket A with the 2 bolts. Torque : 2.0 Nm (20 kgf-cm, 17 in-lbf) 2. INSTALL MULTI-MEDIA INTERFACE ECU (a) Connect the connector. (b) Install the multi-media interface ECU with the nut. Torque : 8.0 Nm (81 kgf-cm, 70 in-lbf) 3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Air Conditioning System (for Automatic Air Conditioning System) Control Module HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 895 Variable Valve Timing Actuator Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION 1. INSTALL VVT SENSOR (a) Install the 4 sensors with the 4 bolts. Page 1324 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 414 Oxygen Sensor Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (A/F) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the A/F fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the A/F fuse. (b) Measure the resistance of the A/F sensor heater relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 9117 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 1380 Impact Sensor: Testing and Inspection Front Airbag Sensor SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE INSPECTION 1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If the front airbag sensor has defects as mentioned below, replace it with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. 3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: * For removal and installation procedures of the front airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the front airbag sensor on the side in which the collision occurred. Replace both if necessary. Air Conditioning System (for Automatic Air Conditioning System) Blower Motor: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 172 Symbols Used Within Diagrams Symbols Used Within Diagrams 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 6671 Diode: Diagrams Diode (Ignition) Page 3441 (a) Reconnect the J86 No. 1 junction connector connector. NEXT -- Continue to next step. 4. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR SIDE) (a) Disconnect the J113 No. 2 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) OK -- Continue to next step. 5. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) (a) Disconnect the J94 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 9336 This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L) and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown. Repair Procedure 1. Remove and replace the air cleaner lid. 2. Remove and replace the front right hand (RH) fender liner. Page 5946 Ignition Switch: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 9212 Page 5571 Page 5425 Control Module: Diagrams Page 5033 HINT Measure at 3 or more positions around the circumference of the ring gear. (b) If the backlash is not within the specification, adjust or repair the side bearing preload as necessary. 4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (a) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05 to 0.20 mm (0.00197 to 0.00788 in.) (b) If the backlash is not within the specified value, replace the side gear thrust washer with one of a different thickness. 5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Standard drive pinion preload (at starting): 0.85 to 1.37 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf) (b) If necessary, disassemble and inspect the differential. 6. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact. Standard total preload (at starting): Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf) (b) If necessary, disassemble and inspect the differential. Page 3551 INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (STEERING ANGLE SENSOR BRANCH WIRE) (a) Disconnect the J6 steering angle sensor connector. Page 7979 (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Components SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY: COMPONENTS Removal SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 7. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (a) Remove the 4 bolts and remove the instrument panel airbag. Page 486 Starter Relay: Testing and Inspection 1UR-FE STARTING: STARTER RELAY: ON-VEHICLE INSPECTION 1. REMOVE STARTER RELAY (ST) (a) Remove the engine room relay box cover. (b) Remove the starter relay from the engine room relay block. 2. INSPECT STARTER RELAY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the relay. 3. INSTALL STARTER RELAY Page 4774 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 4128 Page 2773 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. Emissions - MIL ON/Multiple Air Injection DTC's Set Air Injection Check Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set T-SB-0350-09 Rev1 October 1, 2009 Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 # Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB REVISION NOTICE May 21, 2010 Rev1: ^ DTCs P0418 and P0419 have been added to the TSB. ^ The Applicable Warranty has been updated in the Warranty Information section. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use the following procedure to address this condition. Parts Information Production Change Information Page 4162 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag(s) Arming and Disarming Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.) Components Hood Latch Release Cable: Service and Repair Components ENGINE HOOD / DOOR: HOOD LOCK CONTROL CABLE ASSEMBLY: COMPONENTS Page 1038 Cargo Lamp Switch: Diagrams Engine - Controls - Non-Linear Acceleration From A Stop PROM - Programmable Read Only Memory: Customer Interest Engine - Controls - Non-Linear Acceleration From A Stop T-SB-0273-10 September 28, 2010 Non-Linear Acceleration from a Stop Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear acceleration from a stop under certain conditions of low engine rpm with high engine load. The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised to address this condition. Use the following repair procedure to recalibrate the ECM (PCM). Calibration Information Warranty Information Applicable Warranty ^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Components Fuel Pump Control Unit: Service and Repair Components 1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS Page 1473 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 285 4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. B -- Go to step 6 A -- Continue to next step. 5. DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Go to step 7 6. PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT -- Continue to next step. 7. CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT -- Continue to next step. 8. ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT -- Continue to next step. 9. CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT -- END 2. CUSTOMER PROBLEM ANALYSIS HINT * In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. * Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. * The following 5 questions are important points in the problem analysis: Page 8500 6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 2718 (a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter protector, 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. 11. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1) (a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic converter protector and 4 No. 1 converter protector stays. 12. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter protector, 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. 13. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2) (a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic converter protector and 4 No. 1 converter protector stays. Installation 1UR-FE EXHAUST: EXHAUST PIPE (except Regular Cab Standard Deck): INSTALLATION 1. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 1) (a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays. (b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts. Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) HINT Install the monolithic converter protector within the angle range specified in the illustration. 2. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1) Page 7493 Tire Pressure Sensor: Diagrams Page 1182 Knock Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION 1. INSTALL KNOCK SENSOR (a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position. (b) Connect the 4 sensor connectors. 2. INSTALL SEPARATOR CASE (a) Install the separator case with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 3. INSTALL INTAKE MANIFOLD (a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Installation. Page 6701 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 9253 HINT Tape the screwdriver tip before use. 2. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH (a) Using a screwdriver, detach the 2 clips and rear upper door armrest base panel. Then disconnect the connector. HINT Tape the screwdriver tip before use. 3. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Detach the 4 claws and remove the power window regulator switch. 4. REMOVE REAR DOOR FRAME GARNISH LH (a) Detach the 4 clips and remove the rear door frame garnish. 5. REMOVE COURTESY LIGHT ASSEMBLY (a) Detach the claw and remove the courtesy light from the door trim. Page 7761 (c) Remove the instrument panel reinforcement. (1) for Driver Side: Remove the 3 bolts and 3 caps. (2) for Passenger Side: Using a T40 "TORX" socket, remove the 2 "TORX" bolts. HINT When removing the bolts, the collars may come off with the bolts. (3) for Passenger Side: Using a 12 mm hexagon wrench, remove the 2 collars. Page 6534 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 3488 NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (AIR CONDITIONING AMPLIFIER) OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY Problem Symptoms Table CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS TABLE HINT * Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. * Inspect the fuses and relays related to this system before inspecting the suspected areas below. Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Locations Ignition Relay: Locations MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Page 6212 Installation OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): INSTALLATION 1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply) (a) Attach the 2 claws to install the power outlet socket. 2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard) (a) Attach the 2 claws to install the power outlet socket cover. 3. INSTALL REAR POWER OUTLET SOCKET (for Standard) (a) Attach the claw to install the power outlet socket. 4. INSTALL CONSOLE BOX BEZEL Page 6052 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 7370 (a) Fully extend the rear shock absorber rod. (b) Using a drill, make a hole in the cylinder between A and B shown in the illustration to discharge the gas inside. CAUTION: Be careful when drilling because shards of metal may fly about. Always use the proper safety equipment. NOTICE: The gas is colorless, odorless and nonpoisonous. Page 5462 Transfer Case Actuator: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 6995 Driver Side J/B - Cowl Side Left Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Locations Seat Position Sensor: Locations SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 3710 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. Components Yaw Rate Sensor: Service and Repair Components BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS Components Ambient Temperature Sensor / Switch HVAC: Service and Repair Components AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: COMPONENTS Page 6496 J/B No.3 - Instrument Panel Right Page 4947 Torque Converter: Testing and Inspection A760F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE: INSPECTION 1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the 1-way clutch. (1) Install SST to the inner race of the 1-way clutch. SST : 09350-32014 09351-32020 (2) Press on the serrations of the stator with a finger and rotate it. Check that the stator rotates smoothly when turned clockwise and locks when turned counterclockwise. If the results are not as specified, clean the converter and recheck the 1-way clutch. If the results still are not as specified, replace the torque converter clutch assembly. (b) Determine the condition of the torque converter clutch. (1) Check that the following conditions are met: * During the stall test or when the shift lever is in N, metallic sounds are not emitted from the torque converter clutch. * The 1-way clutch turns in one direction and locks in the other direction. * The amount of powder in the ATF is not more than the sample shown in the illustration. (2) If the results are not as specified, replace the torque converter clutch assembly. HINT The sample illustration shows approximately 0.25 liters (0.26 US qts, 0.22 Imp. qts) of ATF taken from a removed torque converter clutch. Page 3545 Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (POWER STEERING ECU BRANCH WIRE) (a) Disconnect the J101 power steering ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE POWER STEERING ECU BRANCH WIRE OR CONNECTOR (CANH, CANL) OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - BATTERY AND BODY GROUND) (a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. (b) Disconnect the J101 power steering ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: (d) Measure the voltage according to the value(s) in the table below. Standard voltage: Page 6920 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 3983 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Wire and Wire In Engine Compartment Multiple Junction Connector: Locations Wire and Wire In Engine Compartment AB1-RA3 Page 6809 Multiple Junction Connector: Connector Views Frame Wire Page 391 Components Cabin Temperature Sensor / Switch: Service and Repair Components AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System): COMPONENTS Page 3469 * If CAN communication system DTCs are output, the trouble cannot be determined solely from the DTCs. Perform troubleshooting according to "HOW TO PROCEED WITH TROUBLESHOOTING" See: Initial Inspection and Diagnostic Overview/CAN Communication System/How to Proceed With Troubleshooting (a) MULTIPLEX TILT AND TELESCOPIC ECU HINT DTC communication uses the CAN communication system. (b) MAIN BODY ECU HINT DTC communication uses the CAN communication system. (c) ECM HINT The ECM is connected to the CAN communication system but CAN communication DTCs are not output. (d) SKID CONTROL ECU WITH ACTUATOR HINT DTC communication uses the CAN communication system. (e) COMBINATION METER ECU HINT DTC communication uses the CAN communication system. (f) AIR CONDITIONING AMPLIFIER HINT DTC communication uses the CAN communication system. (g) STEERING ANGLE SENSOR HINT Page 4236 Accelerator Pedal Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 615 Parking Assist Switch: Service and Repair Removal PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE DRIVE MONITOR SWITCH (a) Detach the 2 claws and remove the monitor switch. Page 3229 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 1416 (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. A760F Automatic Transmission System Transfer Case Actuator: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Components Control Module: Service and Repair Components JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS Service and Repair Fuel Pressure Release: Service and Repair 1UR-FE FUEL: FUEL SYSTEM: PRECAUTION CAUTION: * Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. * Do not smoke or be near an open flame when working on the fuel system. * Keep gasoline away from rubber and leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: * Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. * After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment. (a) Disconnect the cable from the negative (-) battery terminal. (b) Disconnect the 2 fuel pump ECU connectors. (c) Connect the cable to the negative (-) battery terminal. (d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT DTC P0171/0174 (system too lean) may be set. (e) Crank the engine again, then check that the engine does not start. (f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. (g) Connect the 2 fuel pump ECU connectors. 2. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow these procedures. (1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. (2) Put a container under the connecting part of the pressure line. (3) Slowly loosen the connection. (4) Disconnect the connection. (5) Plug the connection with a rubber plug. (b) Observe these precautions when removing and installing the injectors: Page 5393 Control Module: Diagrams Locations Steering Column Control Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 1095 Page 3887 Transmission Position Switch/Sensor: Diagrams Page 4586 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 1831 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 3084 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 8051 Clockspring Assembly / Spiral Cable: Service and Repair Installation SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: INSTALLATION 1. INSTALL SPIRAL CABLE (a) Attach the 3 claws and install the spiral cable with steering sensor. NOTICE: When replacing the spiral cable with a new one, remove the lock pin before installing the steering wheel. (b) Connect the connectors to the spiral cable with steering sensor. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 2. INSTALL UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 3. INSTALL LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 4. ADJUST SPIRAL CABLE (a) Check that the ignition switch is OFF. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Rotate the spiral cable with steering sensor counterclockwise slowly by hand until it feels firm. Power Mirror Control System (w/ Memory) Heated Mirror Switch: Locations Power Mirror Control System (w/ Memory) MIRROR: POWER MIRROR CONTROL SYSTEM (w/ Memory): PARTS LOCATION Page 8631 Double Cab)/Installation. (b) for Regular Cab: Install the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (c) for CrewMax: Install the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 5203 NOTICE: * Install the washer with its tapered surface facing downward. * Install the retainer with its chamfered surface facing downward. (b) Using SST and a press, press in the rear axle shaft. SST : 09631-12090 SST : 09726-40010 SST : 09951-01100 NOTICE: Make sure to securely fit the bearing to the rear axle shaft. 4. INSTALL REAR AXLE SHAFT SNAP RING (a) Using a snap ring expander, install a new snap ring. Components Wiper Switch: Service and Repair Components WIPER AND WASHER: WIPER SWITCH: COMPONENTS Page 1242 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 3883 Throttle Position Sensor: Diagrams Page 8423 Accessory Relay: Diagrams Page 2312 1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): REMOVAL 1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Removal. 2. SET NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and Repair/Overhaul/Disassembly 3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH See: Camshaft (for Bank 1)/Removal 4. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH See: Camshaft (for Bank 1)/Removal 5. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH See: Camshaft (for Bank 1)/Removal 6. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH See: Camshaft (for Bank 1)/Removal 7. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole. (c) Remove the 2 bolts and chain tensioner. 8. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH 9. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH (a) Remove the 2 bolts and vibration damper. 10. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH Page 3670 Parts Information Calibration Information Required Tools & Equipment Repair Procedure Page 6191 2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly 4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL (a) for AC Power Supply: Disconnect the clamp. (b) Remove the 4 screws and bezel. 5. REMOVE REAR POWER OUTLET SOCKET (for Standard) (a) Detach the claw and remove the power outlet socket. 6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard) (a) Detach the 2 claws and remove the power outlet socket cover. 7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply) (a) Detach the 2 claws and remove the power outlet socket. Page 5099 Parts Information Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle when driving. ^ Install ChassisEAR(TM) (or equivalent) and isolate noise to the rear differential area. ^ Remove the rear differential and axle shafts. Page 2057 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. Page 8161 Page 6407 Console Box Wire Engine Wire Page 1403 Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the door airbag sensor with the screw. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the door airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the door airbag sensor. (e) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly 7. INSTALL REAR SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Install the side airbag sensor with the bolt. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Locations Switch: Locations JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Page 4378 Fuel Pump Control Unit: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 5968 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Page 4210 Page 3879 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Page 5870 Parking Brake Warning Switch: Diagrams Page 8217 (1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. HINT Do not connect the yellow connector. The yellow connector is used to connect to the seat belt pretensioner. (2) Press SST activation switch and check that the LED of SST activation switch illuminates. CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be malfunctioning. Replace SST with a new one. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the cable from the negative (-) battery terminal. (2) Remove the front door scuff plate See: Removal and Replacement/Front Seat Outer Belt Assembly (for CrewMax)/Removal. (3) Remove the rear door scuff plate See: Removal and Replacement/Front Seat Outer Belt Assembly (for CrewMax)/Removal. (4) Remove the front door opening trim weatherstrip See: Removal and Replacement/Front Seat Outer Belt Assembly (for CrewMax)/Removal. (5) Remove the rear door opening trim weatherstrip. (6) Remove the lower center pillar garnish See: Removal and Replacement/Front Seat Outer Belt Assembly (for CrewMax)/Removal. (7) Disconnect the pretensioner connector as shown in the illustration. (d) Prepare SST for activation of the seat belt pretensioner. (1) Install the floor anchor of the seat belt. (2) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner. Up to 11/2009 Parking Brake Warning Switch: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8577 Removal PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 3. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal Floor Speaker (for CrewMax) Speaker: Service and Repair Floor Speaker (for CrewMax) Components AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): COMPONENTS Removal AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 1530 Power Steering Pressure Switch: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: REMOVAL 1. REMOVE FAN AND GENERATOR V BELT (a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DRAIN POWER STEERING FLUID 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the power steering oil pressure switch connector. (b) Remove the power steering oil pressure switch. (c) Remove the O-ring. Page 5080 Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent HINT Install the actuator within 10 minutes of applying seal packing. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the actuator onto the differential tube. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (g) Install the 4 bolts. Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) Page 4140 IV. Background There is a possibility that certain accelerator pedal mechanisms may in rare instances mechanically stick in a partially depressed position or return slowly to the idle position. Over time some accelerator pedal mechanisms may become worn. As a result of this wear combined with certain operating and environmental conditions friction in the mechanism may increase and intermittently result in the accelerator pedal being hard to depress slow to return or in the worst case stick in a partially open position. Page 8183 Page 6341 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 8436 Removal AUDIO / VISUAL: RADIO ANTENNA: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE ANTENNA ORNAMENT Page 9066 when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT Page 9035 Trailer Towing Part 2 Air Conditioning System (for Automatic Air Conditioning System) Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Automatic Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Page 5131 3. Inspect the front differential support bolt for separation. Repair Procedure 1. If the differential support bolt is separated perform the five steps below. NOTE If there is NO damage to the differential support bolt, this TSB does NOT apply. Continue diagnosis to isolate the cause of the condition. A. Remove the differential support bolt. Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: B. Clean the bracket and surrounding area. C. Install the NEW differential support bolt. Refer to TIS applicable model and model year Repair Manual: Torque: 120 N*m (1224 kgf*cm, 89 ft*lbf) Page 8498 Removal DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL 1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 4. REMOVE FRONT DOOR SCUFF PLATE RH Page 7751 Page 6829 Page 8967 Remote Switch: Testing and Inspection AUDIO / VISUAL: STEERING PAD SWITCH: INSPECTION 1. INSPECT STEERING PAD SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the steering pad switch assembly. Page 7610 Step 4. Remove the cover by sliding up while pulling toward you Step 5. Remove the filter cover. Page 2144 Tire Pressure Monitor Receiver / Transponder: Diagrams Page 9149 Page 5318 Shift Interlock Control Module: Diagrams Components Engine Temperature Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: COMPONENTS Page 1099 Telescopic Steering Column)/Installation 8. INSTALL LOWER STEERING COLUMN COVER (for Manual Tilt) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation 9. INSTALL LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation 10. INSTALL LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering Column) See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 11. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation 12. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 13. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 14. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 15. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 17. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 4988 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and makes an operating noise. OK: (c) If the result is not as specified, replace the solenoid valve. 8. INSPECT SHIFT SOLENOID VALVE SLT (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: Page 7202 Steering Control Module: Diagrams Locations Tilt Wheel Switch: Locations STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN SYSTEM: PARTS LOCATION Specifications Crankshaft Main Bearing: Specifications CRANKSHAFT Temporarily install the 10 main bearing cap bolts to the inside positions. Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal bearing cap bolts as a guide. Bolt length............................................................................................................................................. .........................................................91 mm (3.58 in.) Temporarily install the 10 main bearing cap bolts to the outside positions. Bolt length............................................................................................................................................. ......................................................79.5 mm (3.13 in.) The main bearing cap bolts are tightened in 2 progressive steps. Step 1: Uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration. For inside position - Torque.................................................................................................................. ....................................61 Nm (622 kgf-cm, 45 ft-lbf) For outside position - Torque................................................................................................................ ....................................27 Nm (275 kgf-cm, 20 ft-lbf) If any of the main bearing cap bolts do not meet the specified torque, replace it. Page 6772 Multiple Junction Connector: Locations Wire and Wire In Seat [Bench Seat] JT1 JT1 Page 5727 Brake Hose/Line: Service and Repair Rear Brake Flexible Hose Components BRAKE: REAR BRAKE FLEXIBLE HOSE: COMPONENTS Removal BRAKE: REAR BRAKE FLEXIBLE HOSE: REMOVAL HINT * Use the same procedures for the LH side and RH side. Page 6494 Driver Side J/B - Cowl Side Left Page 193 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 3330 HINT The wavelength becomes shorter as engine rpm increases. (i) WAVEFORM 8: HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10 minutes or more. (j) WAVEFORM 9: Page 8281 * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL REAR SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Align the adjuster positioning hole with the claw, and install the adjuster with the 2 bolts. HINT First install the upper bolt, and then install the lower bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Align the vehicle's claws with the seat belt retractor positioning holes. (b) Install the seat belt with the 2 bolts. HINT First install bolt A, and then install bolt B. for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Install the shoulder anchor with the nut. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 3. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 4. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY Page 802 Steering Angle Sensor: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6307 J/B No.6 Assembly Inner Circuit Page 4010 (4) Check that air flows from port A to port B. If the result is not as specified, replace the air switching valve. Page 383 NG -- REPLACE RELAY OK -- Continue to next step. 3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step. 4. INSPECT ECM (IGSW VOLTAGE) (a) Disconnect the ECM connectors. (b) Turn the ignition switch to ON. (c) Measure the voltage according to the value(s) in the table below. Page 2073 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 5739 BRAKE CONTROL: BRAKE ACTUATOR: INSTALLATION NOTICE: In case of replacing the skid control ECU, perform the zero point calibration of the steering angle sensor, master cylinder pressure sensor, and yaw rate and deceleration sensor See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning 1. INSTALL VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY (a) Install the VSC actuator with actuator bracket with the 3 nuts. NOTICE: Do not drop the actuator. If dropped, replace it. (b) Tighten the 3 nuts uniformly in alphabetical order. Torque : 22 Nm (224 kgf-cm, 16 ft-lbf) 2. CONNECT BRAKE TUBE (a) Set each brake line to the correct position on the brake actuator as shown in the illustration. HINT * *1: FR RH * *2: FR LH * *3: RR RH * *4: RR LH * *5: FR Master Cylinder * *6: RR Master Cylinder (b) Install a new clamp onto the VSC actuator bracket. (c) Using a union nut wrench, connect the 4 brake tubes. Torque : 15 Nm (155 kgf-cm, 11 ft-lbf) Locations Power Distribution Module: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 6063 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 8444 (c) for Regular Cab: Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 4754 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 3664 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 5076 09956-03020 37. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using SST to hold the companion flange. SST : 09330-00021 09330-00030 (b) Coat the threads of a new nut with hypoid gear oil. (c) Install the nut by tightening it until the standard preload is reached. Torque : 451 Nm (4599 kgf-cm, 332 ft-lb for less) (d) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Standard preload (at starting): (e) If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached. Torque : 451 Nm (4599 kgf-cm, 332 ft-lb for less) (f) If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. HINT Do not loosen the nut to reduce the preload. 38. INSPECT TOTAL PRELOAD (a) With the drive pinion contacting the tooth side of the ring gear, use a torque wrench to measure the total preload. Page 3472 Page 6145 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Locations Power Distribution Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 2798 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 9270 (b) Connect the hood lock control cable. (c) Install the hood lock. (d) Install the 2 bolts and nut. Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf) (e) Install a new cap. (f) w/ Theft Deterrent System: Connect the connector. 4. INSTALL HOOD LOCK CONTROL CABLE COVER (a) Attach the clamp to install the cable cover. (b) Install the screw and nut. Page 7669 Reassembly AIR CONDITIONING: COMPRESSOR (for 1UR-FE): REASSEMBLY 1. INSTALL MAGNET CLUTCH ASSEMBLY (a) Install the magnet clutch stator with the parts shown in the illustration matched. (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. (c) Connect the connector. (d) Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. NOTICE: Do not damage the seal cover of the bearing when installing the snap ring. (e) Install the compressor washer(s) and magnet clutch hub. NOTICE: Do not change the combination of the compressor washer(s) used before disassembly. (f) Using SST, hold the magnet clutch hub and install the bolt. SST : 09985-00270 Page 24 Alarm Module: Service and Repair Installation THEFT DETERRENT: THEFT WARNING ECU: INSTALLATION 1. INSTALL GLASS BREAKAGE SENSOR ECU (a) Install the ECU with the nut. (b) Install the junction block with the 2 nuts. (c) Connect the connectors. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (a) for Column Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Remove the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 3. INSTALL INSTRUMENT SIDE PANEL LH Page 6988 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 4533 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY (a) Connect the 3 connectors. (b) Install the integration relay to the engine room relay block. (c) Install the engine room relay block cover. Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Inspection Variable Valve Timing Actuator: Testing and Inspection Inspection 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the camshaft timing oil control valve assembly. (c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and check the movement of the valve. OK: (d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC may be output. Page 772 Acceleration/Deceleration Sensor: Service and Repair Removal BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Removal 3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type) (a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 4. REMOVE YAW RATE SENSOR (a) Remove the 2 nuts (labeled A) and sensor. (b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the sensor bracket. Locations Starter Relay: Locations 1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION Specifications Spark Plug: Specifications SPARK PLUG Using a 16 mm plug wrench, install the 8 spark plugs. Torque.................................................................................................................................................. .....................................21 Nm (214 kgf-cm, 15 ft-lbf) GAP Engine - MIL ON/DTC's P0012/P0022 Set Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set T-SB-0019-10 January 20, 2010 MIL "ON" DTC P0012 and/or P0022 Service Category Engine/Hybrid System Section Engine Control Market USA Applicability Introduction Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing Over-Retarded Bank 1/2). Please refer to the following repair procedure to address this condition. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Production Change Information Page 6651 (a) for AC Power Supply: Disconnect the clamp. (b) Remove the 4 screws and bezel. 5. REMOVE REAR POWER OUTLET SOCKET (for Standard) (a) Detach the claw and remove the power outlet socket. 6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard) (a) Detach the 2 claws and remove the power outlet socket cover. 7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply) (a) Detach the 2 claws and remove the power outlet socket. Components Fuel Pump Control Unit: Service and Repair Components 1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS Page 7819 Control Module HVAC: Service and Repair Removal AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE RH (a) for Regular Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 3. REMOVE COWL SIDE TRIM BOARD RH (a) for Regular Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) for Column Shift Type: Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 5. REMOVE INSTRUMENT SIDE PANEL RH (a) for Column Shift Type: Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Body/Frame - Choppy Ride Under Various Conditions Body / Frame Mount Bushing: Customer Interest Body/Frame - Choppy Ride Under Various Conditions T-SB-0270-10 September 13, 2010 Choppy Ride Service Category Vehicle Exterior Section Frame/Unibody Market USA Applicability Introduction Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road conditions. A newly designed cab mount has been developed to improve this condition. NOTE The Tundra performs similarly to other long wheelbase trucks on choppy, broken concrete surfaces. The enhanced cab mounts of this TSB reduce the amplitude of body vibrations caused by uneven road surfaces, but they do NOT eliminate the sensation entirely. Customers should be counseled that they will experience an improvement in the condition and their truck will perform better than competitors in identical conditions, but some body Page 2453 Intake Manifold: Testing and Inspection 1UR-FE INTAKE: INTAKE SYSTEM: ON-VEHICLE INSPECTION 1. INSPECT INTAKE AIR CONTROL VALVE (a) Remove the V-bank cover. (b) Start the engine. (c) While the engine is idling, check that the actuator rod moves as shown in the illustration. (d) Disconnect the VSV connector, and check that the actuator rod returns. If the operation is not as specified, inspect the intake air control valve, VSV and ECM. (e) Connect the VSV connector. (f) Install the V-bank cover. 2. INSPECT INTAKE AIR CONTROL VALVE (a) Inspect the diaphragm. (1) Using a vacuum pump, apply a vacuum of 60 kPa (450 mmHg, 17.7 in.Hg). Check that the lever moves. If the result is not as specified, replace the intake air surge tank. 3. CHECK AIR INDUCTION SYSTEM HINT The illustration shows the areas that may draw in secondary air, which could lead to idling problems. (a) Check that the hoses are installed correctly. (b) Check for cracks, etc. in the hoses. Page 2111 B -- GO TO VC OUTPUT CIRCUIT See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/VC Output Circuit A -Continue to next step. 7. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Disconnect the ECM connector. (b) Disconnect the combination meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal Page 3434 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU WITH ACTUATOR (CANH, CANL) OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal 16. CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR) (a) Disconnect the J6 steering angle sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE SENSOR (CANH, CANL) OK -- REPLACE STEERING ANGLE SENSOR 17. CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU) (a) Disconnect the J101 power steering ECU connector. Page 4389 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection Page 6666 Auxiliary Power Outlet Switch: Service and Repair Installation OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION 1. INSTALL INVERTER MAIN SWITCH (a) Attach the 2 claws to install the main switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Diagrams Electronic Noise Suppressor: Diagrams Components Acceleration/Deceleration Sensor: Service and Repair Components BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS Components Transmission Speed Sensor: Service and Repair Components A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS Locations Main Relay (Computer/Fuel System): Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 1716 (d) * for 5 leaf spring Standard steering axis inclination (unloaded vehicle): for Regular Cab of Standard Deck Page 7741 7. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the damper servo with the 3 screws. (b) Connect the connector. 8. INSTALL DAMPER SERVO SUB-ASSEMBLY (a) Install the servo motor. (1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to install the main plate. (2) Install the 2 screws. (b) Install the servo motor. Page 1821 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 2008 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 8243 Removal SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTICE: Page 7282 POWER STEERING: STEERING GEAR: INSTALLATION 1. INSTALL POWER STEERING GEAR ASSEMBLY (a) Install the power steering gear with the 2 bolts and 2 nuts. Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf) 2. INSTALL PRESSURE FEED TUBE ASSEMBLY (a) Temporarily connect the pressure feed tube to the power steering gear. (b) Install the pressure feed tube clamp with the 2 bolts. Torque : 28 Nm (286 kgf-cm, 21 ft-lbf) (c) Using a union nut wrench, tighten the pressure feed tube (pressure feed tube side). Page 451 Air Bag Control Module: Locations Airbag System SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION Page 2353 Page 1477 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 3678 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 720 Removal SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT SEAT ASSEMBLY LH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Removal. 2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 3. REMOVE RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 4. REMOVE FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly 5. REMOVE FRONT POWER SEAT LUMBAR SWITCH LH (a) Remove the 2 screws and switch. Installation SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT POWER SEAT LUMBAR SWITCH LH Page 5310 Flex Plate: Specifications DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Install and uniformly tighten 10 new bolts in the sequence shown in the illustration. Torque.................................................................................................................................................. .....................................30 Nm (301 kgf-cm, 22 ft-lbf) Mark the top of each drive plate installation bolt with paint. Tighten the drive plate installation bolts 90° as shown in the illustration. Check that the painted marks are now at a 90° angle to the top. Page 7526 2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the noise loudest near the rear wheel bearing assembly? ^ YES - Go to step 3. ^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise. 3. Replace the rear wheel bearing caliper bracket and related parts. Refer to the Technical Information System (TIS) applicable model year Repair Manual: 4. Test drive the vehicle and confirm the noise is eliminated. 5. Re-check rear differential oil level and confirm NO leaks are present. Removal and Replacement Valve Body: Removal and Replacement Components A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS Removal Page 6971 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 3707 ^ 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 7151 Tire Pressure Sensor: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so that the print surface can be seen. NOTICE: * Check that there is no visible deformation, damage or other abnormalities on the tire pressure warning valve and transmitter. * Check that there is no foreign matter on the inner grommet and around the rim hole. * If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be damaged or fail to transmit signals when running at a high speed. * If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before installation. * The transmitter ID registration must be performed for all tire pressure warning valve and transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do not need to be replaced before performing the transmitter ID registration See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration * It is necessary to perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after registration See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been replaced. (b) If reusing the tire pressure warning valve and transmitter: Install a new grommet. HINT A new tire pressure warning valve and transmitter is supplied with a grommet. (c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut. Page 259 Symbols Used Within Diagrams Symbols Used Within Diagrams Locations Collision Avoidance System Switch: Locations PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION Page 7950 * When removing the front passenger airbag, work must be started 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery. * When storing the front passenger airbag, keep the airbag deployment side facing upward. (c) Install SST. (1) After connecting SST each other, connect them to the front passenger airbag. SST : 09082-00802 09082-10801 09082-30801 (d) Using a service-purpose wire harness for the vehicle, tie down the front passenger airbag to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.00193 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front passenger airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2). HINT To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Position the front passenger airbag inside the tire with the airbag deployment side facing inside. Locations Fuel Pump Relay: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 274 Push the terminal retainer down to the temporary lock position. Page 1176 Knock Sensor: Diagrams Page 9001 Page 496 Steering Column Control Module: Service and Repair Removal STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power Telescopic Steering Column): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE UPPER STEERING COLUMN COVER (a) Remove the 2 screws. HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws. (b) Detach the 4 clips. (c) Detach the claw to remove the upper steering column cover. 3. REMOVE LOWER STEERING COLUMN COVER (a) Detach the 2 claws to remove the lower steering column cover. 4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Latch Release Cable/Service and Repair/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal Page 8376 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front CAN Communication System Body Control Module: Locations CAN Communication System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION Tires - Pressure Compensation And Adjustment Tires: Technical Service Bulletins Tires - Pressure Compensation And Adjustment T-SB-0345-08 Rev2 November 6, 2008 Tire Inflation Pressure Compensation and Adjustment Service Category Suspension Section Tire/Wheel Market USA Applicability TSB REVISION NOTICE ^ December 22, 2009 Rev2: ^ Applicability has been updated to include 2010 model year Prius PHV model and 2011 vehicles. Any previous printed versions of this service bulletin should be discarded. TSB REVISION NOTICE ^ May 15, 2009 Rev1: ^ Applicability has been updated to include 2010 model year vehicles, and 2009 - 2010 model year Venza. ^ Figure 1 has been updated, and Celsius temperatures have been removed from the bulletin. Any previous printed versions of this service bulletin should be discarded. Page 2657 Engine Temperature Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSTALLATION 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket to the sensor. (b) Using a 19 mm ball joint lock nut wrench, install the sensor. Torque : 20 Nm (200 kgf-cm, 14 ft-lbf) NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench See: Service Precautions (c) Connect the sensor connector. 2. ADD ENGINE COOLANT See: Coolant/Service and Repair 3. INSPECT FOR COOLANT LEAK See: Testing and Inspection 4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation 5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service and Repair/Replacement Page 4701 Transmission Speed Sensor: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION 1. INSTALL SPEED SENSOR SP2 (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. 2. INSTALL SPEED SENSOR NT (a) Coat a new O-ring with ATF and install it to the sensor. (b) Install the sensor with the bolt. Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf) (c) Connect the sensor connector. Page 2816 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK Page 883 Oil Pressure Sender: Testing and Inspection 1UR-FE LUBRICATION: OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT OIL PRESSURE SENDER GAUGE ASSEMBLY (a) Disconnect the sender gauge connector. (b) Apply battery positive (+) voltage to the sender gauge terminal through a test LED. (c) Check that the LED does not illuminate when the engine is stopped. (d) Check that the LED flashes when the engine is running. The number of flashes varies with engine speed. If the operation is not as specified, replace the oil pressure sender gauge assembly. Page 9014 "Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 7113 Tire Pressure Monitor Receiver / Transponder: Diagrams Page 2169 Tire Pressure Warning Reset Switch: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING RESET SWITCH (a) Attach the 2 claws to install the reset switch. (b) Connect the switch connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Oil Pressure Sender Oil Pressure Sender: Diagrams Oil Pressure Sender Components Alarm Module: Service and Repair Components THEFT DETERRENT: THEFT WARNING ECU: COMPONENTS Page 3487 (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result NG -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE) OK -- Continue to next step. 15. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (POWER STEERING ECU) OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair/Removal 16. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE) (a) Disconnect the J19 air conditioning amplifier connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Locations Transmission Mode Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 3696 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 6345 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 2724 (d) Remove the 2 gaskets from the front exhaust pipes. 3. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 4. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Removal 5. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (a) Remove the 2 bolts and 2 nuts. (b) Disconnect the front No. 3 exhaust pipe from the exhaust pipe support. (c) Remove the front No. 3 exhaust pipe from the front No. 2 exhaust pipe. (d) Disconnect the air fuel ratio sensor connector. (e) Remove the 3 nuts, front No. 2 exhaust pipe and 2 gaskets from the exhaust manifold LH. 6. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor/Removal 7. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Disconnect the air fuel ratio sensor connector. (b) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH. 8. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Air Fuel Ratio Sensor/Removal 9. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Using SST, remove the sensor. SST : 09224-00010 10. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 1) Page 2523 Torque.................................................................................................................................................. .....................................47 Nm (479 kgf-cm, 35 ft-lbf) Tighten the 23 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the illustration. Torque.................................................................................................................................................. .....................................23 Nm (235 kgf-cm, 17 ft-lbf) Page 6739 Driver Side J/B - Cowl Side Left Page 2543 Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: 2. Verify the vehicle has the proper coolant and oil levels. 3. Clear all DTCs and confirm the condition has been corrected. Page 7732 Evaporator Temperature Sensor / Switch: Service and Repair Disassembly AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: DISASSEMBLY 1. REMOVE AIR CONDITIONING UNIT (a) Remove the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Removal. 2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY (a) Detach the 4 claws and remove the nozzle. 3. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (a) Detach the 4 claws and remove the duct. 4. REMOVE AIR FILTER COVER PLATE (a) Detach the 2 clips and remove the plate. 5. REMOVE CLEAN AIR FILTER Specifications Brake Fluid: Specifications Brake Fluid Type ..................................................................................................................................................... .................... SAE J1703 or FMVSS No. 116 DOT 3 Page 5916 Torque : 11 Nm (107 kgf-cm, 8 ft-lbf) NOTICE: * Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part. * While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip part. * After installing the speed sensor, make sure there is no clearance or foreign matter between the sensor stay part and the knuckle. * Make sure there is no foreign matter attached to the magnetic rotor. 6. INSTALL FRONT SKID CONTROL SENSOR WIRE RH (a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B). for Bolt B - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf) (b) Install the connector (labeled C) with connect the connector (labeled C). (c) Install the 2 harness clamps (labeled D) with the 2 bolts (labeled E). for Bolt E - Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamps, do not twist the wire harness. * For clamps with rotation stoppers, make sure the rotation stopper touches the installation position. (d) Install the harness clamp with the bolt (labeled E). Torque : 13 Nm (127 kgf-cm, 9 ft-lbf) NOTICE: * When installing the clamp, do not twist the wire harness. * Make sure the clamp's rotation stopper touches the installation position. Components Four Wheel Drive Selector Switch: Service and Repair Components JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS Components Remote Switch: Service and Repair Components AUDIO / VISUAL: STEERING PAD SWITCH: COMPONENTS Page 1721 (c) Read the adjustment chart (example). (1) Find the wheel alignment standard value applicable for the particular model. (2) Mark the selected standard value on the adjustment chart. Standard value (reference): (3) Mark the alignment value measured when the vehicle is unloaded on the adjustment chart. Measured value (reference): (4) As shown in the chart, read the distance from the marked point to 0, and adjust the front and/ or rear adjusting cams accordingly. Amount to turn adjusting cams (by gradation): Page 8951 4. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 5. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 6. REMOVE REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 7. REMOVE REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 8. REMOVE REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 9. REMOVE REAR BUMPER COVER (for Resin Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal 10. REMOVE REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Rear Bumper/Service and Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal 11. REMOVE NO. 1 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. HINT The type of claw on the top and bottom of the sensor are different. Observe the claws carefully before removing the sensor. 12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER (a) Detach the 2 claws and remove the sensor retainer from the rear bumper. 13. REMOVE NO. 2 ULTRASONIC SENSOR (a) While pushing down on the lever with a finger to release the one claw, detach the claw on the other side to remove the ultrasonic sensor. Page 2328 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 7915 Air Bag: Diagrams Instrument Panel Airbag Assembly Lower Page 4290 Parts Information Calibration Information Required Tools & Equipment Repair Procedure A/T - World Standard Automatic Transmission Fluid Fluid - A/T: Technical Service Bulletins A/T - World Standard Automatic Transmission Fluid T-SB-0006-11 January 6, 2011 World Standard Automatic Transmission Fluid Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. TC010-07. Applicability has been updated to include 2009 - 2011 model year Toyota vehicles. TSB No. TC010-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction World Standard (WS) Automatic Transmission Fluid (ATF) was introduced to reduce maintenance costs and increase the mileage between scheduled maintenance checks. Here are some important tips when working with ATF-WS in Toyota vehicles requiring its use. Warranty Information Page 4555 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 7734 10. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the 4 screws and damper servo. (c) Remove the damper servo. (1) Detach the claw and remove the main plate. (2) Remove the 2 screws and damper servo. (d) Remove the damper servo. Page 3945 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 8275 (a) Remove the bolt and belt. 3. REMOVE REAR SEAT INNER BELT ASSEMBLY (a) Remove the bolt and belt. Installation SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for Double Cab): INSTALLATION 1. INSTALL REAR SEAT INNER BELT ASSEMBLY (a) Install the belt with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body. 2. INSTALL REAR NO. 1 SEAT INNER BELT ASSEMBLY RH (a) Install the belt with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body. Page 7890 Solar Sensor: Service and Repair Removal AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): REMOVAL 1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Detach the 2 claws. (b) Disconnect the connector and remove the sensor. Page 3468 C -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN Communication System/Problem Symptoms Table A -- Continue to next step. 10. CHECK DTC COMBINATION TABLE (V BUS CIRCUIT BRANCH WIRE OPEN PAST MALFUNCTION) (a) Based on the combination of stored CAN communication system DTCs, determine which ECUs and sensors have a communication stop malfunction See: Initial Inspection and Diagnostic Overview/CAN Communication System/Diagnosis System. NEXT -- Continue to next step. 11. PERFORM MALFUNCTION SIMULATION TEST (V BUS CIRCUIT MAIN WIRE PAST MALFUNCTION)* (a) Using the Techstream, clear all DTCs. (b) Perform a malfunction simulation test on all harnesses and connectors related to the V bus circuit main wire. (c) Check the DTCs that were output as a result of the malfunction simulation test. Then determine the malfunctioning area. NEXT -- Continue to next step. 12. ADJUST, REPAIR AND REPLACE NEXT -- Continue to next step. 13. CONFIRMATION TEST NEXT -- END Diagnosis System CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: DIAGNOSIS SYSTEM 1. BUS CHECK (a) Select "CAN Bus Check" from the "System Select". 2. CHECK INSTALLED SYSTEMS (ECUS AND SENSORS) THAT USE CAN COMMUNICATION (a) Systems (ECUs and sensors) that use CAN communication vary depending on the vehicle's optional settings. Check which systems (ECUs and sensors) are installed on the vehicle. 3. DTC TABLE BY ECU HINT * In the CAN communication system, CAN communication system DTCs output by the ECU can be displayed by using the Techstream. Page 6794 Establish conditions in which voltage is present at the check point. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (SW2 off) 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. Electronic Circuit Inspection Procedure Page 480 Seat Occupant Classification Module - Air Bag: Service and Repair Removal SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: REMOVAL 1. REMOVE FRONT SEAT ASSEMBLY RH (a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Removal. 2. REMOVE OCCUPANT CLASSIFICATION ECU (a) Disconnect the connector. (b) Detach the claw and remove the ECU from the seat. Drivetrian - Rear End Howling/Growling Noises Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises T-SB-0151-10 June11, 2010 Rear Axle Bearing Abnormal Noise Service Category Drivetrain Section Axle/Differential Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Page 8234 Connect the connector and attach the clamp. 2. INSTALL FRONT SEAT INNER CUSHION SHIELD (for Manual Seat) See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly 3. INSTALL FRONT SEAT ASSEMBLY (for Power Seat) (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 4. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat) (a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY (for Center Seat): COMPONENTS Page 3221 Data Link Connector: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 3628 Oxygen Sensor Relay: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE INSPECTION 1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection 2. INSPECT INTEGRATION RELAY (A/F) NOTICE: * Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. * The internal circuit of the integration relay is as shown in the illustration below. Inspect the integration relay using the following procedures. (a) Measure the resistance of the A/F fuse. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the A/F fuse. (b) Measure the resistance of the A/F sensor heater relay. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Diagrams Radio Tuner: Diagrams Page 7033 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 1159 Crankshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Page 2040 Driver Side J/B Inner Circuit Page 794 Parking Brake Warning Switch: Testing and Inspection PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking Brake System/Parking Brake Pedal/Service and Repair/Overhaul/Disassembly 2. CHECK PARKING BRAKE SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the parking brake switch assembly. 3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking Brake System/Parking Brake Pedal/Service and Repair/Overhaul/Reassembly Page 2015 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 8661 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. Page 8108 Page 7598 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. (a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. HINT * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. How To Proceed With Troubleshooting INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO PROCEED WITH TROUBLESHOOTING 1. OPERATION FLOW HINT Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT -- Continue to next step. 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. Page 4997 (a) Install the shift solenoid valve with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) 6. INSTALL SHIFT SOLENOID VALVE SL1 7. INSTALL SHIFT SOLENOID VALVE SLT (a) Install the shift solenoid valve. (b) Install the 2 straight pins and lock plate with the bolt. Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf) 8. INSTALL SHIFT SOLENOID VALVE SLU 9. INSTALL SHIFT SOLENOID VALVE SL2 Page 2814 Standard Voltage: NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) OK -- REPLACE ECM See: Service and Repair/Removal 5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY AND BODY GROUND) (a) Disconnect the ECM connector. (b) Disconnect the ignition switch connector. (c) Disconnect the cable from the battery positive (+) terminal. (d) Remove the AM2 fuse and integration relay. Page 2915 Camshaft Position Sensor: Service and Repair Installation 1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (b) Connect the sensor connector. 2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation Diagrams Brake Fluid Level Sensor/Switch: Diagrams Page 6365 Multiple Junction Connector: Connector Views Frame Wire Oil Pressure Sender Oil Pressure Sender: Diagrams Oil Pressure Sender Page 8082 Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor. (e) Connect the connector. 8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 11. INSTALL REAR SEAT ASSEMBLY (for Rear Side) (a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Installation. 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 3516 C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal Short to GND in CAN Bus Line CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short to GND in CAN Bus Line Short to GND in CAN Bus Line DESCRIPTION There may be a short circuit between the CAN bus line and GND when there is resistance between terminals 6 (CANH) and 4 (CG) or terminals 14 (CANL) and 4 (CG) of the DLC3. HINT * *1: w/ Bus Buffer ECU * *2: w/ 4WD * *3: w/ Power Steering ECU WIRING DIAGRAM Page 5022 Page 2243 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 230 Turn Signal Relay: Diagrams Page 2305 (b) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTICE: * Be careful not to damage the cylinder head with the wrench. * Do not disassemble the camshaft timing gear. (c) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTICE: Be careful not to damage the cylinder head with the wrench. (d) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH. (e) Remove the No. 1 and No. 2 chains from the gears. 7. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (a) Remove the 2 bolts and chain tensioner. 8. REMOVE CAMSHAFT BEARING CAP LH (a) Make sure that the knock pin of the camshaft is positioned as shown in the illustration. (b) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Page 2066 Push the terminal retainer down to the temporary lock position. Components Fuel Pressure Regulator: Service and Repair Components 1UR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS Page 4273 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 6041 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 5843 Acceleration/Deceleration Sensor: Programming and Relearning BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION 1. DESCRIPTION * After replacing components relating to the VSC or performing "Front wheel alignment adjustment", clear and read the sensor calibration data. * Follow the chart to perform calibration. 2. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING TECHSTREAM) (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. (c) Operate the Techstream to erase the codes (select Reset Memory). HINT Refer to the Techstream operator's manual for further details. 3. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND DECELERATION SENSOR (WHEN USING TECHSTREAM) NOTICE: * While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it stationary. (Do not start the engine.) * While obtaining the zero point, do not depress the brake and accelerator pedal. * Obtain the zero point on a level surface (with an inclination of 1° or less). (a) Enter Test Mode. (1) Turn the ignition switch off. (2) Check that the shift lever is in parking or neutral and apply the parking brake. CAUTION: Application of the parking brake is not necessary for entering test mode. However, apply the parking brake for safety. (3) Connect the Techstream to the DLC3. (4) Turn the ignition switch to ON. NOTICE: Do not start the engine. (5) Set the Techstream to test mode (select Test Mode). HINT Refer to the Techstream operator's manual for further details. (b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor. (1) Keep the vehicle stationary on a level surface for 1 second or more. HINT Page 2484 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 6658 Removal OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 3. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal 4. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Page 1560 Tire Pressure Warning Reset Switch: Diagrams Page 6968 DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. 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. Page 3209 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 3599 Manifold Pressure/Vacuum Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR (a) Disconnect the manifold absolute pressure sensor connector. (b) Remove the screw and manifold absolute pressure sensor. (c) Remove the O-ring from the manifold absolute pressure sensor. Page 1163 Crankshaft Position Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL 1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR (a) Remove the 2 bolts and sensor protector. 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. Page 2048 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 9256 Up to 11/2009 ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): REASSEMBLY REAR DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Connect the 2 cables to the inside handle. (b) Attach the inside handle's knob to the door trim board. (c) Attach the 9 clips to install the door trim board. (d) Install the inside handle and door trim board to the door trim panel with the screw. (e) Install the door trim board to the door panel with the screw (f) Attach the clip. 2. INSTALL REAR DOOR ARMREST COVER LH 3. INSTALL COURTESY LIGHT ASSEMBLY (a) Connect the connector. Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Capacity Front (4WD models) Capacity ............................................................................................................. .............................................................................................. 2.2 qt (2.05L) Rear Regular Cab Models Standard Bed ............................................................................................ ......................................................................................................... 4.3 qt (4.05L) Long Bed ............. .............................................................................................................................................................. ................................ 4.9 qt (4.60L) Double Cab and Crew Max Models Capacity ...................................................................................... .................................................................................................................... 4.9 qt (4.60L) Page 7066 8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: * Some systems need to be initialized after the cable is reconnected ( See: Testing and Inspection/Programming and Relearning). * After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal. 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and Inspection/Programming and Relearning 10. PERFORM YAW RATE AND DECELERATION SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate and deceleration sensor zero point calibration See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning. 11. CHECK STEERING ANGLE SENSOR ZERO POINT CALIBRATION Page 1700 (b) : for 5 leaf spring Measuring points: A Ground clearance of the front drive shaft center B Ground clearance of the front adjusting cam bolt center C Ground clearance of the rear axle shaft center D Ground clearance of the leaf spring front side bushing center (c) If the vehicle height is not as specified, adjust the height by pressing down on the vehicle several times to stabilize the suspension. 3. INSPECT TOE-IN Page 5295 (b) Remove the grease fitting from the spider bearing. (c) Using a brass bar and hammer, slightly tap in the 4 spider bearings. (d) Using needle-nose pliers, remove the 4 snap rings from the grooves. (e) Using a screwdriver, remove the 4 slingers of the spider bearing. (f) Clamp the shaft in a vise between aluminum plates. (g) Using SST, pull out the universal joint spider bearing from the shaft. SST : 09331-60010 SST : 09950-40011 09951-04010 09952-04010 09953-04020 Page 6710 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 5110 Actuator: Service and Repair Installation DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): INSTALLATION 1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator. (b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol. (c) Apply seal packing to the differential tube as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent HINT Install the actuator within 10 minutes of applying seal packing. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the actuator onto the differential tube. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (g) Install the 4 bolts. Torque : 21 Nm (210 kgf-cm, 15 ft-lbf) (h) Connect the actuator hose. (i) Connect the actuator connector. 2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and Inspection/Component Tests and General Diagnostics/Touch Select 2-4 and High-Low System. Components Crankshaft Position Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS Components Power Steering Pressure Switch: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: COMPONENTS Page 3320 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK Page 2971 5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft Assembly/Removal 6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor connector. (b) Disconnect the air fuel ratio sensor connector. (c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support. (d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH. 7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) for 2WD: Disconnect the air fuel ratio sensor connector. (b) Using SST, remove the sensor. SST : 09224-00010 Installation 1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION 1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Install the sensor to the exhaust pipe by hand. (b) Using SST, tighten the sensor. SST : 09224-00010 Page 3657 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Transponder Key ECU Alarm Module: Diagrams Transponder Key ECU Page 5285 Removal PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: REMOVAL 1. REMOVE PROPELLER SHAFT HEAT INSULATOR Page 3672 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Testing and Inspection Canister Purge Control Valve: Testing and Inspection 1UR-FE EMISSION CONTROL: PURGE VALVE: INSPECTION 1. INSPECT PURGE VSV (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the purge VSV. (c) Inspect the purge VSV operation. (1) Check that air does not flow from ports. (2) Apply battery voltage across the terminals. (3) Check that air flows from ports. If the result is not as specified, replace the purge VSV. Page 3216 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 7594 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 5526 Transmission Speed Sensor: Diagrams Page 6161 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 4370 SST : 09268-31012 90467-13001 95336-08070 09268-41500 09268-41120 SST : 09268-45014 09268-41200 09268-41220 (g) Wipe off any gasoline. (h) Reconnect the cable to the negative (-) battery terminal. (i) Operate the fuel pump. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. NOTICE: Do not start the engine. (3) Turn the Techstream main switch ON. (4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (j) Measure the fuel pressure. Standard fuel pressure: 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi) (k) If the pressure is higher than the specification, replace the fuel pressure regulator. If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator assembly. (l) Start the engine. Testing and Inspection Drive Belt: Testing and Inspection 1UR-FE ENGINE MECHANICAL: DRIVE BELT: ON-VEHICLE INSPECTION 1. INSPECT FAN AND GENERATOR V BELT (a) Check the belt for wear, cracks or other signs of damage. (b) If any of the following defects is found, replace the fan and generator V belt. * The belt is cracked. * The belt is worn out to the extent that the cords are exposed. * The belt has chunks missing from the ribs. (c) Check that the belt fits properly in the ribbed grooves. HINT Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and generator V belt correctly. 2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY (a) Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If the result is not as specified, replace the tensioner. Page 8971 Remote Switch: Service and Repair Installation AUDIO / VISUAL: STEERING PAD SWITCH: INSTALLATION 1. INSTALL STEERING PAD SWITCH ASSEMBLY (a) Attach the 4 pins to install the switch with the 2 screws. (b) Connect the connector. 2. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 3. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 4. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. INSPECT STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation 7. CHECK SRS WARNING LIGHT See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Installation Page 3453 Information Bus: Component Tests and General Diagnostics Air Conditioning Amplifier Communication Stop Mode CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Air Conditioning Amplifier Communication Stop Mode - Air Conditioning Amplifier Communication Stop Mode DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor communication with the CAN, which causes resistance variation. PROCEDURE 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of the main wire and the branch wire. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NEXT -- Continue to next step. 2. CHECK FOR OPEN IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE) (a) Disconnect the J19 air conditioning amplifier connector. Page 7226 Steering Control Module: Service and Repair Installation POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION 1. INSTALL POWER STEERING ECU ASSEMBLY (a) Install the power steering ECU with the nut. Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf) (b) Connect the power steering ECU connector. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation Page 9228 (e) Remove the inside handle. Reassembly ENGINE HOOD / DOOR: FRONT DOOR (for Regular Cab): REASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (a) Connect the 2 cables to the inside handle. (b) Attach the inside handle's knob to the door trim board. (c) Attach the 10 clips to install the door trim board. (d) Install the inside handle and door trim board to the door trim panel with the screw. (e) Install the door trim board to the door panel with the screw. Page 7022 for Regular Cab of Long Deck for Double Cab of Standard Deck Components Seat Occupant Classification Module - Air Bag: Service and Repair Components SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: COMPONENTS Page 7291 (a) Install SST onto the power steering rack. SST : 09631-20111 HINT If necessary, scrape the burrs off the power steering rack teeth end and burnish. (b) Coat SST with power steering fluid. (c) Install the power steering rack into the rack housing. (d) Remove SST. 4. INSTALL POWER STEERING RACK BUSH (a) Using SST and a press, install a new rack bush oil seal onto the rack bush. SST : 09950-60010 09951-00440 SST : 09950-70010 09951-07100 NOTICE: Make sure that the rack bush oil seal is installed facing the correct direction. (b) Coat a new O-ring with power steering fluid and install it onto the rack bush. (c) To prevent the rack bush oil seal lip from being damaged, wind vinyl tape around the rack end and apply power steering fluid. Page 2202 Tire Pressure Sensor: Diagrams Page 6353 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Door Control Switch (for Front LH) Power Door Lock Switch: Testing and Inspection Door Control Switch (for Front LH) DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): INSPECTION 1. INSPECT DOOR CONTROL SWITCH ASSEMBLY (for Regular Cab) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the control switch assembly. 2. INSPECT DOOR CONTROL SWITCH ASSEMBLY (for Double Cab) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 1666 (4) Connect the battery's positive (+) lead to terminal B-1 (+S) for 5 seconds. (5) Connect the battery's negative (-) lead to terminal B-1 (+S). Operate the intermittent wiper relay and check the voltage between terminals B-3 (+1) and A-2 (EW). OK: Refer to illustration below. (6) If the result is not as specified, replace the switch assembly. (d) Check the washer operation. (1) Turn the wiper switch OFF. (2) Connect the battery's positive (+) lead to terminal B-2 (+B) and the negative (-) lead to terminals B-1 (+S) and A-2 (EW). (3) Connect the voltmeter's positive (+) lead to terminal B-3 (+1) and the negative (-) lead to terminal A-2 (EW). (4) Turn the washer switch ON and OFF, and check the voltage between terminals B-3 (+1) and A-2 (EW). OK: Refer to illustration below. (5) If the result is not as specified, replace the switch assembly. Page 8066 Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Front Airbag Sensor SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE INSPECTION 1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If the front airbag sensor has defects as mentioned below, replace it with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. Page 1262 Air Flow Meter/Sensor: Diagrams Page 3866 Throttle Position Sensor: Diagrams Page 7620 (a) Detach the 2 claws and remove the sensor. Recall 11V185000 - TPMS Non-Compliance Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011 Toyota/Tundra 2009-2011 MANUFACTURER: Gulf States Toyota, Inc. MFR'S REPORT DATE: March 16, 2011 NHTSA CAMPAIGN ID NUMBER: 11V185000 NHTSA ACTION NUMBER: N/A COMPONENT: Tires: Pressure Monitoring and Regulating Systems POTENTIAL NUMBER OF UNITS AFFECTED: 1,489 SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year 2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may not have been properly calibrated and as a result the low tire pressure warning lamp may not illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold for when the low tire pressure warning lamp should illuminate. CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or more tires are underinflated increasing the risk that a vehicle will be driven with one or more underinflated tires and increasing the risk of a tire failure that may lead to a crash. REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the regulation free of charge. The safety recall is expected to begin during April 2011. Owners may contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 3496 (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU WITH ACTUATOR (CANH, CANL) OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Removal 16. CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR) (a) Disconnect the J6 steering angle sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE SENSOR (CANH, CANL) OK -- REPLACE STEERING ANGLE SENSOR 17. CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU) (a) Disconnect the J101 power steering ECU connector. Page 7059 Standard caster inclination (unloaded vehicle): for CrewMax of standard deck Page 8405 Seat Occupant Sensor: Diagrams Rear Occupant Classification Sensor Page 2704 Page 8171 Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 7036 *: for 5 leaf spring Standard Steering Angle Inclination for Regular Cab of Standard Deck Page 2959 Engine Bank Identification Page 2616 Spark Plug: Service and Repair Installation 1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION 1. INSTALL SPARK PLUG (a) Using a 16 mm plug wrench, install the 8 spark plugs. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) 2. INSTALL IGNITION COIL ASSEMBLY (a) for Bank 1: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors. (3) Connect the 3 wire harness clamps. (b) for Bank 2: (1) Install the 4 ignition coils with the 4 bolts. Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) (2) Connect the 4 ignition coil connectors and 2 wire harness clamps. (3) Connect the water by-pass pipe with the 2 bolts. Torque : 18 Nm (184 kgf-cm, 13 ft-lbf) Page 862 Engine Temperature Sensor: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR: INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Partially immerse the sensor in water and warm up the water. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: (c) If the result is not as specified, replace the engine coolant temperature sensor. NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the sensor dry. HINT If the result is as specified, do not replace the engine coolant temperature sensor. Page 404 (b) Spray gasket remover or equivalent on the remaining tape of the gasket. NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth. (c) Remove the tape of the gasket without using bladed objects. Page 9202 Page 7319 SST : 09950-40011 09951-04010 09953-04020 09954-04010 09955-04031 09958-04011 09952-04010 SST : 09955-04090 HINT Claw A 09955-04090 Claw B 09955-04031 Installation SUSPENSION: FRONT LOWER SUSPENSION ARM: INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * A bolt without a torque specification is shown in the standard bolt chart See: Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts 1. TEMPORARILY INSTALL FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH Page 8802 * The procedures listed below are for the LH side. 1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) (a) Attach the 3 claws to install the speaker to the bracket. NOTICE: Do not touch the cone part of the speaker. (b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws. 2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 4 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 4. INSTALL FRONT DOOR ARMREST COVER LH 5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for CrewMax)/Reassembly 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Page 4178 Page 8569 Removal and Replacement Suspension Spring ( Coil / Leaf ): Removal and Replacement Components SUSPENSION: REAR LEAF SPRING: COMPONENTS Page 8222 (2) Press SST activation switch and check that the LED of SST activation switch illuminates. CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be malfunctioning. Replace SST with a new one. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the cable from the negative (-) battery terminal. (2) Remove the front door scuff plate See: Removal and Replacement/Front Seat Outer Belt Assembly (for Double Cab)/Removal. (3) Remove the rear door scuff plate See: Removal and Replacement/Front Seat Outer Belt Assembly (for Double Cab)/Removal. (4) Remove the front door opening trim weatherstrip See: Removal and Replacement/Front Seat Outer Belt Assembly (for Double Cab)/Removal. (5) Remove the rear door opening trim weatherstrip See: Removal and Replacement/Front Seat Outer Belt Assembly (for Double Cab)/Removal. (6) Remove the lower center pillar garnish See: Removal and Replacement/Front Seat Outer Belt Assembly (for Double Cab)/Removal. (7) Disconnect the pretensioner connector as shown in the illustration. (d) Prepare SST for activation of the seat belt pretensioner. (1) Install the floor anchor of the seat belt. (2) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner. SST : 09082-00700 SST : 09082-00770 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Components Auxiliary Power Outlet Switch: Service and Repair Components OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS Page 5148 Seals and Gaskets: Service and Repair Front Differential Carrier Oil Seal Components DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER OIL SEAL (for 4WD): COMPONENTS Page 7701 9. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 11. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 12. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 13. INSTALL FRONT PILLAR GARNISH LH 14. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (Double cab, CrewMax) 15. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (for Regular Cab) 16. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. 17. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Regular Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Double Cab: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (c) for CrewMax: Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. 18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 19. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Check Mode Procedure. Page 1425 Removal SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Page 3937 This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown. Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, this repair is covered under the California Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Page 3635 Power Steering Pressure Switch: Testing and Inspection 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION 1. INSPECT POWER STEERING OIL PRESSURE SWITCH (a) Check the oil pressure switch. (1) Connect the Techstream to the DLC3. (2) Turn the ignition switch to ON. (3) Turn the Techstream main switch on. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering pressure. (5) Start the engine. (6) Operate the steering wheel while idling, and read the value on the Techstream. Standard: (7) If not as specified, check for DTCs See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Inspect the power steering system See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection results are normal and a DTC is not output, replace the power steering oil pressure switch. Page 7845 (a) Detach the 2 claws and remove the sensor. Page 281 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Engine - Oil Filter Cap Assembly Precaution Oil Filter: Technical Service Bulletins Engine - Oil Filter Cap Assembly Precaution T-SB-01 04-09 April 10, 2009 Oil Filter Cap Assembly Precautions Service Category Engine/Hybrid System Section Lubrication Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. T-SB-0332-08. ^ Applicability has been updated to include 2009 - 2010 model year Highlander, 2010 model year Camry, Corolla, Matrix, Sequoia, Tundra, and 2009 model year Venza vehicles. ^ The SST table has been updated with an illustration. ^ The Notice in the Repair Procedure has been updated with a Figure and torque specification ranges to clarify SST usage. TSB No. T-SB-0332-08 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction To prevent damage to the oil filter cap assembly this procedure must be closely followed during oil filter replacement to avoid immediate and future oil filter serviceability concerns. The following engines are equipped with a plastic oil filter cap assembly: ^ 1UR-FE (Tundra Sequoia) ^ 3UR-FE (Tundra Sequoia Land Cruiser) ^ 2ZR-FE (Corolla Matrix) Page 1479 "Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Page 6287 If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B -- SYSTEM NORMAL A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. Page 8182 Seat Occupant Classification Module - Air Bag: Locations Occupant Classification System SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS LOCATION Page 2627 Water Pump: Service and Repair Removal 1UR-FE COOLING: WATER PUMP: REMOVAL 1. REMOVE FAN SHROUD (a) Remove the fan shroud See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal. 2. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT (a) Remove the water inlet with thermostat See: Cooling System/Thermostat/Service and Repair/Removal. 3. REMOVE FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service and Repair/Removal 4. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Removal 5. REMOVE WATER BY-PASS PIPE (w/ Oil Cooler) (a) Remove the 2 bolts. (b) Disconnect the 4 water hoses and remove the water by-pass pipe. 6. REMOVE NO. 1 WATER BY-PASS HOSE (a) Remove the water by-pass hose. 7. DISCONNECT NO. 8 WATER BY-PASS HOSE (a) Disconnect the water by-pass hose. 8. DISCONNECT NO. 5 WATER BY-PASS HOSE (a) Disconnect the water by-pass hose. 9. REMOVE WATER INLET HOUSING Page 4292 ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. Page 672 (b) Disconnect the power window regulator master switch connector. 2. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Remove the 3 screws and master switch. Installation DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): INSTALLATION 1. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Install the master switch with the 3 screws. Page 4343 Components Power Steering Pressure Switch: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH: COMPONENTS Adjustments Parking Assist Control Module: Adjustments PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: ADJUSTMENT 1. ADJUST BUZZER VOLUME (a) Turn the knob on the clearance warning ECU to adjust the volume. Page 1400 Page 8822 Removal AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly Page 8166 Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type) SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): ON-VEHICLE INSPECTION 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow the correct procedure. HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact. Page 7005 Driver Side J/B Inner Circuit Page 8365 Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BATTERY (a) Disconnect the cable from the positive (+) battery terminal. Page 4790 ^ 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 7192 Power Steering Pump: Overhaul Disassembly POWER STEERING: VANE PUMP (for 1UR-FE): DISASSEMBLY 1. FIX VANE PUMP ASSEMBLY (a) Using SST, hold the vane pump in a vise. SST : 09630-00014 09631-00132 2. REMOVE POWER STEERING SUCTION PORT UNION (a) Remove the bolt and suction port union from the vane pump. (b) Using a screwdriver, remove the O-ring from the suction port union. 3. REMOVE VANE PUMP REAR HOUSING (a) Remove the 4 bolts and rear housing from the front housing. (b) Using a screwdriver, remove the O-ring from the rear housing. Page 6551 Driver Side J/B - Cowl Side Left Locations Knock Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 6194 Auxiliary Power Outlet: Service and Repair Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Page 8751 Required Tools & Equipment Repair Procedure Overview ^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed. ^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing. ^ Remove the rear axle shaft assembly. ^ Install new rear wheel bearing brake caliper bracket and seals. ^ Reinstall rear axle shaft assembly and confirm the noise is no longer present. Repair Procedure 1. Test drive the vehicle and confirm the customer complaint. Does the noise increase and decrease with vehicle speed? ^ YES - Go to step 2. ^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis. Page 522 Tire Pressure Module: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Engine Control System - SFI System Crankshaft Position Sensor: Locations Engine Control System - SFI System 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Locations Throttle Position Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 9312 Lower Side Moulding / Trim: Service and Repair Installation EXTERIOR: SIDE MOULDING: INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. * When installing the moulding, heat the vehicle body and moulding using a heat light. Standard heating temperature: NOTICE: Do not heat the vehicle body and moulding excessively. 1. INSTALL LOWER NO. 1 SIDE PANEL MOULDING LH (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. (b) If reusing the moulding: Clean the moulding. (1) Using a heat light, heat the moulding. (2) Remove the double-sided tape from the moulding. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the moulding, as shown in the illustration. (c) Install the moulding. (1) Using a heat light, heat the vehicle body and moulding. (2) Remove the peeling paper from the face of the moulding. HINT After removing the peeling paper, keep the exposed adhesive free from foreign matter. Page 360 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 688 (a) Inspect the outer mirror switch. (1) Select "L" on the left/right adjustment switch. (2) Measure the resistance according to the value(s) in the table below. Standard resistance: (3) If the result is not as specified, replace the outer mirror switch. (4) Select "R" on the left/right adjustment switch. (5) Measure the resistance according to the value(s) in the table below. Standard resistance: (6) If the result is not as specified, replace the outer mirror switch. (b) Inspect the retract switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 2788 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Components Refrigerant Pressure Sensor / Switch: Service and Repair Components AIR CONDITIONING: PRESSURE SWITCH: COMPONENTS Page 6746 Engine Room R/B And Engine Room J/B Inner Circuit Page 6704 Front Occupant Classification Sensor Seat Occupant Sensor: Diagrams Front Occupant Classification Sensor Page 8148 Page 7317 Removal SUSPENSION: FRONT LOWER SUSPENSION ARM: REMOVAL HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSEMBLY LH See: Stabilizer Bar/Service and Repair/Removal 3. DISCONNECT FRONT SHOCK ABSORBER WITH COIL SPRING LH Page 1646 (a) Using a screwdriver, detach the 2 clips and 5 claws, and remove the front upper armrest base panel. HINT Tape the screwdriver tip before use. (b) Disconnect the 2 connectors. 2. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Detach the 2 claws and remove the regulator switch. Page 1363 Air Bag Deactivation Switch: Testing and Inspection Curtain Shield Airbag Cutoff Switch SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH: INSPECTION 1. INSPECT CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 5963 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 1517 Neutral Safety Switch: Service and Repair Installation A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the switch to the manual valve shaft. (b) Temporarily install the bolt. (c) Install a new lock washer and the nut. Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf) (d) Temporarily install the control shaft lever RH. (e) Turn the control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position. (f) Align the groove with the neutral basic line. Page 5016 Actuator: Service and Repair Removal DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD): REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal 2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (a) Disconnect the actuator hose. (b) Disconnect the actuator connector. (c) Remove the 4 bolts and actuator. Page 4461 (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the MAF meter. Up to 11/2009 Yaw Rate Sensor: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 5036 (a) Place matchmarks on the bearing cap and differential carrier. (b) Remove the 4 bolts and 2 differential bearing caps. (c) Remove the differential case from the differential carrier. HINT Tag the 2 case bearing outer races to show the location for reassembly. 15. REMOVE REAR DIFFERENTIAL DRIVE PINION (a) Remove the differential drive pinion and bearing spacer from the differential carrier. 16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST and a press, press out the bearing (inner race). SST : 09950-00020 (b) If either the drive pinion or ring gear is damaged, replace them as a set. 17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER 18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using a brass bar and hammer, tap out the bearing (outer race). Page 5197 HINT Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot. (b) Temporarily install a new boot to the outboard joint shaft. (c) Position the inside clamp onto the boot. (d) Using SST, pinch the inside clamp. SST : 09521-24010 NOTICE: Do not overtighten SST. (e) Pack the outboard joint and boot with grease in the boot kit. Standard grease capacity: 292 to 312 g (10.3 to 11.0 oz.) (f) Position the outside clamp onto the boot. (g) Using SST, pinch the outside clamp. SST : 09521-24010 NOTICE: Do not overtighten SST. (h) Using SST, adjust the clearance of the clamps. Page 7000 J/B No.6 Assembly - Instrument Panel Center Locations Cabin Temperature Sensor / Switch: Locations AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System): PARTS LOCATION Locations Tire Pressure Warning Reset Switch: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 3380 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 280 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 1964 (8) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1 (9) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2 (10)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out. (11)Tighten the bleeder plug completely. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (12)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for RH. (c) Bleed VSC actuator assembly NOTICE: After bleeding the air from the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding of the brake actuator with the Techstream by following the procedure below. (1) Depress the brake pedal more than 20 times with the engine off. (2) Connect the Techstream to the DLC3, and turn the ignition switch on. NOTICE: Do not start the engine. (3) Select AIR BLEEDING on the Techstream. HINT Refer to the Techstream operator's manual for further details. (4) Bleed the air out of the suction line. NOTICE: * Perform the bleeding at the right front wheel and right rear wheel. * Bleed the air by following the steps displayed on the Techstream. (5) 1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel. 2. Loosen the bleeder plug. 3. Operate the brake actuator to bleed the air using the Techstream. HINT This operation stops automatically after 4 seconds. NOTICE: Release the brake pedal at this time. (6) 4. Check if the operation has stopped by referring to the Techstream display. 5. Temporarily tighten the bleeder plug. 6. Repeat the 4 previous steps until all in the fluid is completely bled out. 7. Tighten the bleeder plug. Torque : 11 Nm (110 kgf-cm, 8 ft-lbf) (7) 8. Repeat all of the above procedures for the other wheel to bleed the air out of the suction line. (8) Bleed the air out of the pressure reduction line. NOTICE: * Perform the bleeding at the 4 wheels. * Bleed the air by following the steps displayed on the Techstream. (9) 1. Connect a vinyl tube to one of the bleeder plugs. Components Water Pump: Service and Repair Components 1UR-FE COOLING: WATER PUMP: COMPONENTS Page 4587 [A] For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case1" Raise the terminal retainer up to the temporary lock position. Page 9386 12. Torque the NEW nuts to the specified torque range on the No.2 mounts. Torque: 54 N*m (551 kgf*cm, 40 ft*lbf) 13. Reinstall the body plugs for the cab mount bolt holes and then restore the carpet to its original position. 14. Test drive vehicle to confirm the condition has been improved. Page 2416 ^ 1AR-FE (Highlander Venza) ^ 2AR-FE (RAV4 Camry) Warranty Information Required Tools & Equipment Page 6590 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 7990 Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold Down Seat Type): REMOVAL CAUTION: * Be sure to read Precaution thoroughly before servicing See: Service Precautions * If the side airbag was deployed, replace the front seat assembly with a new one. * Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands. 1. REMOVE FRONT SEAT ASSEMBLY RH (a) Remove the front seat assembly RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Removal. 2. REMOVE FRONT SEAT HEADREST ASSEMBLY RH 3. REMOVE RECLINING ADJUSTER RELEASE HANDLE RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 4. REMOVE FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 5. REMOVE INNER FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 6. REMOVE FRONT SEATBACK LOCK HANDLE LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 7. REMOVE FRONT SEATBACK LOCK HANDLE RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 8. REMOVE FRONT SEATBACK SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 9. REMOVE FRONT SEATBACK SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Disassembly 10. REMOVE FRONT SEATBACK ASSEMBLY RH Page 741 Seat Heater Switch: Service and Repair Installation SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System): INSTALLATION 1. INSTALL SEAT HEATER SWITCH (a) w/ Climate Control Seat System: Attach the 8 claws to install the 2 seat heater switches. (b) w/ Seat Heater System: Attach the 4 claws to install the 2 seat heater switches. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY See: Heating and Air Conditioning/Control Assembly/Service and Repair/Air Conditioning Panel (for Floor Shift Type)/Installation 3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 11. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation Page 2960 A/F and 02 Sensor Identification A760F Automatic Transmission System Control Module: Locations A760F Automatic Transmission System A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 4932 (h) Remove the 2 bolts and then pull the transmission control cable into the vehicle to remove it. Installation A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Column Shift Type): INSTALLATION 1. INSTALL COLUMN SHIFT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Insert the transmission control cable from the vehicle interior, and install the cable retainer with the 2 bolts. Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf) (b) Connect the cable to the steering column shaft bracket so that the claws of the outer cable socket are securely attached. (c) Connect the column shift transmission control cable end to the column shift. Page 5287 (a) for Front Differential Side: (1) Align the matchmarks on the differential and propeller shaft flange. (2) Install the propeller shaft with the 4 washers and 4 nuts. Torque : 80 Nm (816 kgf-cm, 59 ft-lbf) (b) for Transfer Side: (1) Align the matchmarks on the transfer and propeller shaft flange. (2) Connect the propeller shaft with the 4 washers and 4 nuts. Torque : 80 Nm (816 kgf-cm, 59 ft-lbf) 2. INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY (a) Install the heat insulator bracket to the crossmember with the 2 bolts. Torque : 16 Nm (163 kgf-cm, 12 ft-lbf) 3. INSTALL PROPELLER SHAFT HEAT INSULATOR (a) Install the heat insulator to the heat insulator bracket with the 2 bolts. Torque : 16 Nm (163 kgf-cm, 12 ft-lbf) Page 9169 Refer to the service kit instruction sheet for further detail. Technical Service Bulletin # SB0164-10 Date: 100628 Body - Tube Step Step Pad Lifting/Cracking T-SB-0164-10 June 28, 2010 Tube Step - Step Pad Lifting/Cracked Service Category Vehicle Exterior Section Exterior Panels/Trim Market USA Applicability Introduction Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a condition where the step pad has lifted or cracked. To improve the serviceability of the tube step the step pad is now available as a separate service part. Follow the procedure in this bulletin to replace the step pad. Removal of the tube step is not required to perform step pad replacement. Parts Information Warranty Information APPLICABLE WARRANTY ^ Toyota accessories installed as original equipment are 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. ^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months, regardless of mileage, from the date of installation on the vehicle, or the remainder of the applicable New Vehicle Limited Warranty, whichever provides the greater coverage. ^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of purchase. ^ Warranty application is limited to occurrence of the specified condition described in this bulletin. Repair Procedure Page 6864 Power Distribution Module: Service and Repair Removal OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL 1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 6. REMOVE VOLTAGE INVERTER ASSEMBLY (a) Remove the 2 bolts. (b) Disconnect the voltage inverter connector and removal the voltage inverter. Page 7965 NOTICE: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (g) Install SST. (1) Connect SST connector. SST : 09082-00700 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for SST wire harness inside the tire. (h) Deploy the airbag. (1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the curtain shield airbag is tied to. (3) Press SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT The airbag is deployed as the LED of SST activation switch comes on. (i) Dispose of the curtain shield airbag. CAUTION: * The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after Page 6861 Power Distribution Module: Diagrams Voltage Inverter Page 7029 for Regular Cab of Long Deck for Double Cab of Standard Deck Page 45 2. REMOVE REAR DOOR SCUFF PLATE RH (a) Detach the 8 claws and 2 clips, and remove the scuff plate. 3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal 5. REMOVE DOOR CONTROL RECEIVER (a) Disconnect the door control receiver connector. (b) Remove the bolt and receiver. Installation DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION 1. INSTALL DOOR CONTROL RECEIVER (a) Install the receiver with the bolt. (b) Connect the door control receiver connector. 2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 4. INSTALL REAR DOOR SCUFF PLATE RH Locations Air Flow Meter/Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 3559 doors need to be opened in order to check connectors, open the doors and leave them open. 2. JUNCTION CONNECTOR (a) NO. 1 JUNCTION CONNECTOR HINT * *1: w/ Power Steering ECU * *2: for V bus * The connectors connected to the junction connector can be distinguished by the colors of the bus lines and the connecting side of the connector. * The connectors can be connected to any terminals on the same side. (b) NO. 2 JUNCTION CONNECTOR Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Engine - Snow Ingestion Into Air Cleaner Box Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box T-SB-0396-09 December 8, 2009 Snow Entry Into Air Cleaner Box Service Category Engine/Hybrid System Section Intake/Exhaust Market USA Applicability Introduction Some Sequoia and Tundra vehicles operated in areas with significant snow volume may experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air cleaner lid and fender liner have been revised to reduce accumulation. 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 occurrence of the specified condition described in this bulletin. Production Change Information Page 6290 Fuse Block: Connector Views Engine Room R/B, J/B - Engine Compartment Left Page 3726 Page 8630 AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Floor Shift Type): INSTALLATION 1. INSTALL STEREO JACK ADAPTER ASSEMBLY (a) Attach the 2 claws to install the adapter. 2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 3. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning System) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 4. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 5. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 6. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 7. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 8. INSTALL CONSOLE BOX CARPET See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 9. INSTALL REAR CONSOLE END PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 10. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 11. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 12. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 13. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 14. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation 15. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation 16. INSTALL FRONT DOOR SCUFF PLATE LH (a) for Double Cab: Install the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Components Amplifier: Service and Repair Components AUDIO / VISUAL: STEREO COMPONENT AMPLIFIER: COMPONENTS Page 8662 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 7966 deployment. * Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag. * Do not apply water to a curtain shield airbag with a deployed airbag. * Always wash your hands with water after completing the operation. (1) Remove the curtain shield airbag from the tire. (2) Place the curtain shield airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. Front Seat Side Airbag Assembly (for Fold Down Seat Type) SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold Down Seat Type): DISPOSAL HINT When scrapping a vehicle equipped with the SRS or disposing of the front seat side airbag, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: * Never dispose of a front seat side airbag that has an unactivated airbag. * The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. * When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. * When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the airbag. * The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. * Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag. * Do not apply water to a front seat side airbag with a deployed airbag. * Always wash your hands with water after completing the operation. * An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure. 1. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT Prepare a battery as the power source to deploy the airbag. (a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Removal. HINT Keep the front seat in the cabin. (e) Install SST. Audio System - USB/iPod(R) Not Recognized Auxiliary Input / Output Jack: All Technical Service Bulletins Audio System - USB/iPod(R) Not Recognized T-SB-0013-11 February 15, 2011 USB/Pod Not Recognized Service Category Audio/Visual/Telematics Section Audio/Video Market USA Applicability Introduction Some 2010 - 2011 Toyota vehicles may exhibit intermittent operation of USB/iPod(TM) devices while in use. A newly designed Multi-Media Interface ECU has been developed to correct this condition. This bulletin applies to the models shown. This bulletin does not apply to the following models: iPod(TM) mini iPod(TM) shuffle iPod(TM) photo iPhone(TM) and 4th generation and earlier models. These versions of the iPod(TM) are NOT compatible with this system. * iPhone(TM) has limited compatibility with this system. Some functions may not operate properly. Production Change Information Page 5819 Brake Fluid Solenoid Valve Relay: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 6174 Power Outlet [12V] Page 5620 Steering Angle Sensor: Service and Repair Removal BRAKE CONTROL: STEERING ANGLE SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 5. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Steering Pad/Removal 6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 7. REMOVE LOWER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 8. REMOVE UPPER STEERING COLUMN COVER See: Steering and Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal 9. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal 10. REMOVE STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal Page 8628 Removal AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Floor Shift Type): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE LH (a) for Double Cab: Remove the front door scuff plate LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (b) for Regular Cab: Page 8832 (a) Attach the 4 clips and claw to install the speaker panel. 7. INSTALL FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 8. INSTALL FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Components AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): COMPONENTS Page 6966 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Page 6013 Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) (e) If the diameter is less than the minimum, replace the generator rotor assembly. 2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY (a) Using a vernier caliper, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 4.5 mm (0.177 in.) (b) If the exposed length is less than the minimum, replace the generator brush holder assembly. 3. INSPECT GENERATOR DRIVE END FRAME BEARING (a) When rotating the bearing, check that there is no abnormal noise and that it rotates smoothly. (b) If necessary, replace the generator drive end frame bearing. 4. INSPECT GENERATOR ROTOR BEARING (a) When rotating the bearing, check that there is no abnormal noise and that it rotates smoothly. Page 1020 Ambient Light Sensor: Testing and Inspection LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: ON-VEHICLE INSPECTION 1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (a) Connect the voltmeter's positive (+) lead to terminal K19-6 (CLTB) and the negative (-) lead to terminal K19-3 (CLTE). (b) Measure the voltage according to the value(s) in the table below. Standard voltage: (c) Measure the resistance according to the value(s) in the table below. Standard resistance: (d) Reconnect the K19 sensor connector. (e) Check the waveform according to the value(s) in the table below. Waveform: HINT If the ambient light becomes brighter, width A becomes narrower. If the result is not as specified, replace the automatic light control sensor. Page 3195 Camshaft Position Sensor: Locations Ignition System 1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION Up to 11/2009 Brake Fluid Solenoid Valve Relay: Locations Up to 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Page 8247 (a) Attach the 7 clips and 2 claws to install the pillar garnish. (b) Install the seat belt anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Attach the 2 claws to install the cover. 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP 5. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP 6. INSTALL FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 7. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 8. INSTALL FRONT SEAT ASSEMBLY (a) for Manual Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. (b) for Power Seat: Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Page 1952 Refrigerant: Service and Repair AIR CONDITIONING: REFRIGERANT: REPLACEMENT 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (a) Start up the engine. (b) Turn the A/C switch ON. (c) Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor. (d) Stop the engine. (e) Recover the refrigerant from the A/C system using a refrigerant recovery unit. 2. CHARGE REFRIGERANT SST : 09985-20010 09985-02010 09985-02050 09985-02060 09985-02070 09985-02090 09985-02110 09985-02130 09985-02150 (a) Perform vacuum purging using a vacuum pump. (b) Charge refrigerant HFC-134a (R134a). Standard: 600 +/-30 g (21.2 +/-1.1 oz.) NOTICE: Page 9351 Rear Fender Liner: Service and Repair Installation EXTERIOR: FENDER LINER (for Rear Side): INSTALLATION HINT * Use the same procedures for the RH side and LH side. * The procedures listed below are for the LH side. 1. INSTALL REAR WHEEL HOUSE LINER LH (a) Install the rear wheel house liner (front). (1) Install the wheel house liner with 4 new clips. (2) Install the 2 screws. (b) w/o Rear Fender Mudguard: Install the rear wheel house liner (rear). (1) Install the rear wheel house liner with 7 new clips. (2) Install the 2 screws. Components Tire Pressure Warning Reset Switch: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS Page 7426 Tire Pressure Module: Diagrams Page 6402 Page 1999 Fuse Block: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Components Control Module HVAC: Service and Repair Components AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: COMPONENTS Page 2756 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 located on the Technical Information System (TIS), Diagnostics - Battery Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update. 4. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] ^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID] ^ Dealer Code ^ Repair Date ^ Change Authority [This TSB number] B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC P/N 00451-00001-LBL. 5. Test drive the vehicle to confirm proper vehicle operation. Page 1723 (a) Check the steering angle sensor zero point calibration See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/C Code Charts/C1290. Page 3915 (c) Remove the O-ring from the oil control valve. Page 8099 Door/Service and Repair/Front Door (for Double Cab)/Disassembly 4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly 7. REMOVE FRONT SIDE AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the screw and side airbag sensor. 8. REMOVE REAR SEAT ASSEMBLY (for Rear Side) (a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Rear Seat Assembly (for Double Cab)/Removal. 9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side) 11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 12. REMOVE REAR SIDE AIRBAG SENSOR (a) Remove the bolt and side airbag sensor. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): INSTALLATION 1. INSTALL FRONT SIDE AIRBAG SENSOR (a) Check that the ignition switch is OFF. Page 3475 HINT * o: DTC is memorized. * *1: Only during failure status. Fail-Safe Chart CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: FAIL-SAFE CHART 1. FAIL-SAFE FUNCTION (a) When communication fails in any of the main wires (communication lines) due to a short circuit or other causes, the fail-safe function, which is specified for each system, operates to prevent the system from malfunctioning. (b) The table below shows the effects on each system when communication is impossible. For further details, refer to each system. Page 7628 Center Airbag Sensor Assembly (for Floor Shift Type) Impact Sensor: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 3704 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 9067 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. 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 1984 Fuse Block Location - Under The Instrument Panel Fuse Location - Under The Instrument Panel Page 1490 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Components Headlamp Dimmer Switch: Service and Repair Components LIGHTING: HEADLIGHT DIMMER SWITCH: COMPONENTS Page 4907 Page 3606 Page 7993 8. INSTALL FRONT SEATBACK SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 9. INSTALL FRONT SEATBACK SHIELD LH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 10. INSTALL FRONT SEATBACK LOCK HANDLE RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 11. INSTALL FRONT SEATBACK LOCK HANDLE LH 12. INSTALL FRONT SEAT HEADREST ASSEMBLY RH 13. INSTALL INNER FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 14. INSTALL FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 15. INSTALL RECLINING ADJUSTER RELEASE HANDLE RH See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Fold Down Seat Type)/Reassembly 16. INSTALL FRONT SEAT ASSEMBLY RH (a) Install the front seat assembly RH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Fold Down Seat Type)/Installation. 17. PERFORM INITIALIZATION NOTICE: Some systems need initialization after reconnecting the cable to the negative battery terminal See: Testing and Inspection/Programming and Relearning Components SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: COMPONENTS Page 3503 (a) Reconnect the J86 No. 1 junction connector connector. NEXT -- Continue to next step. 4. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR SIDE) (a) Disconnect the J113 No. 2 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR CONDITIONING AMPLIFIER) OK -- Continue to next step. 5. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2 JUNCTION CONNECTOR) (a) Disconnect the J94 No. 1 junction connector connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 8232 Removal SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag. 2. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat) Page 5658 CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. REMOVE REAR WHEEL 3. REMOVE REAR SPEED SENSOR LH (a) Disconnect the speed sensor connector (labeled A). (b) Remove the nut (labeled B) and speed sensor (labeled C). 4. REMOVE REAR SPEED SENSOR RH (a) Disconnect the speed sensor connector (labeled A). (b) Remove the nut (labeled B) and speed sensor (labeled C). 5. REMOVE SKID CONTROL SENSOR WIRE (a) Disconnect the sensor connector (labeled A). (b) Detach the 7 clips (labeled B). (c) Remove the bolt (labeled C). (d) Remove the nut (labeled D) and skid control sensor wire. Installation BRAKE CONTROL: REAR SPEED SENSOR: INSTALLATION Page 3282 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 6765 Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Floor Shift] AJ1-TJ1 Page 5566 Acceleration/Deceleration Sensor: Programming and Relearning BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION 1. DESCRIPTION * After replacing components relating to the VSC or performing "Front wheel alignment adjustment", clear and read the sensor calibration data. * Follow the chart to perform calibration. 2. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING TECHSTREAM) (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON. (c) Operate the Techstream to erase the codes (select Reset Memory). HINT Refer to the Techstream operator's manual for further details. 3. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND DECELERATION SENSOR (WHEN USING TECHSTREAM) NOTICE: * While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it stationary. (Do not start the engine.) * While obtaining the zero point, do not depress the brake and accelerator pedal. * Obtain the zero point on a level surface (with an inclination of 1° or less). (a) Enter Test Mode. (1) Turn the ignition switch off. (2) Check that the shift lever is in parking or neutral and apply the parking brake. CAUTION: Application of the parking brake is not necessary for entering test mode. However, apply the parking brake for safety. (3) Connect the Techstream to the DLC3. (4) Turn the ignition switch to ON. NOTICE: Do not start the engine. (5) Set the Techstream to test mode (select Test Mode). HINT Refer to the Techstream operator's manual for further details. (b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor. (1) Keep the vehicle stationary on a level surface for 1 second or more. HINT Page 3138 * Never reuse the O-ring. * When placing a new O-ring on the injector, do not damage it. * Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and intake manifold as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type). (1) for Fuel Hose Connector Cover Type: Detach the lock claw by lifting up the cover, as shown in the illustration. (2) for Fuel Pipe Clamp Type: Remove the fuel pipe clamp from the fuel tube connector. Page 8823 4. REMOVE FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 5. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 6. REMOVE COURTESY LIGHT ASSEMBLY (w/ Power Window) See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 7. REMOVE FRONT DOOR ARMREST COVER LH 8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly 9. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 4 screws and speaker. NOTICE: Do not touch the cone part of the speaker. Installation AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (a) Temporarily install the speaker by attaching the claws of the speaker to the door panel. (b) Install the speaker with the 4 screws. NOTICE: Do not touch the cone part of the speaker. HINT Install the screws in the order shown in the illustration. (c) Connect the connector. 2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly Page 6033 Symbols Used Within Diagrams Symbols Used Within Diagrams Page 6123 (d) Using a T30 "TORX" socket wrench, install the starter drive housing with the 2 bolts. Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf) 6. INSTALL MAGNET STARTER SWITCH ASSEMBLY (a) Temporarily install the magnet starter switch by hooking its tip to the upper side of the pinion drive lever. (b) Install the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (c) Connect the lead wire to the terminal with the nut. Torque : 6.5 Nm (66 kgf-cm, 57 in-lbf) Page 1412 Page 9104 Trailer Connector: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 7152 Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: * No further tightening is required once the nut is tightened with the specified torque. * Check that there is no foreign matter on the washer and nut. * Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve, washer and nut. Failing to do so may result in improper installation. (d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main body of the tire pressure warning valve and transmitter in the shaded area as shown in the illustration. NOTICE: * If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will interfere with the tire pressure warning valve and transmitter, and may cause damage to it. * If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the tire pressure warning valve and transmitter. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is not clamped by the bead. (f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) NOTICE: Page 7438 Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL 1. REMOVE ROOF HEADLINING ASSEMBLY (a) for Regular Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal. (b) for Double Cab: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal. (c) for CrewMax: Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal. 2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Disconnect the receiver connector. (b) Remove the bolt and receiver. Page 9300 Page 5298 NOTICE: When measuring dimension B, fix the spider and spider bearings in a vise and hold them firmly together. (d) w/o Grease Fitting Spider Bearing: (1) Select snap rings to make dimensions A and B the same. Snap ring type for steel yoke: Snap ring type for aluminum yoke: NOTICE: * Use new snap rings. * If possible, use snap rings of the same thickness for both sides. (e) w/ Grease Fitting Spider Bearing: (1) Select snap rings to make dimensions A and B the same. Snap ring type: Power Steering Oil Pressure Sensor Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor Page 642 (a) Connect the connector. (b) Attach the 4 clips to install the panel. 3. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 5. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY 6. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 8. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 9. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 10. INSTALL COWL SIDE TRIM BOARD LH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. Page 9182 Page 6947 Driver Side J/B Inner Circuit Page 7184 Power Steering Pump: Testing and Inspection POWER STEERING: VANE PUMP (for 1UR-FE): INSPECTION 1. INSPECT VANE PUMP SHAFT AND BUSH IN VANE PUMP FRONT HOUSING (a) Using a micrometer, measure the diameter (a) of the vane pump shaft with vane pump pulley. (b) Using a caliper gauge, measure the inside diameter (b) of the vane pump front housing. (c) Subtract (a) from (b) to calculate the oil clearance. Maximum clearance: 0.07 mm (0.00276 in.) (d) If it is greater than the maximum, replace the vane pump shaft with vane pump pulley. 2. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATE (a) Inspect the vane pump rotor groove and vane pump plate clearance. (1) Using a feeler gauge, measure the clearance between the side face of the vane pump rotor groove and the vane pump plates. Maximum clearance: 0.03 mm (0.00118 in.) (2) If the clearance is more than the maximum, replace the vane pump plates, vane pump rotor and vane pump cam ring. NOTICE: * Check the marks on the vane pump rotor and vane pump cam ring. * Refer to the following table to select an appropriate combination of vane pump rotor, vane pump cam ring and vane pump plates. Combination of vane pump rotor, vane pump cam ring and vane pump plates: Page 2410 9. INSTALL FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Installation 10. ADD ENGINE OIL See: Engine Oil/Service and Repair/Replacement 11. ADD ENGINE COOLANT See: Cooling System/Coolant/Service and Repair 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. INSPECT FOR OIL LEAK See: Engine Oil/Service and Repair/Replacement 14. CHECK ENGINE OIL LEVEL See: Testing and Inspection 15. INSPECT FOR COOLANT LEAK See: Cooling System/Testing and Inspection 16. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement Page 7857 Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Manual Air Conditioning System) AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System): PARTS LOCATION Page 5387 Transfer Case Actuator: Diagrams Page 8059 Impact Sensor: Diagrams Door Side Airbag Sensor Page 7729 Evaporator Temperature Sensor / Switch: Testing and Inspection AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: INSPECTION 1. INSPECT NO. 1 COOLER THERMISTOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NOTICE: * Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. * When measuring, the sensor temperature must be almost the same as the ambient temperature. HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the sensor. Page 1892 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 6045 "Case2" 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 1394 Page 8835 Removal AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Page 4357 7. INSTALL EGR VALVE BRACKET (a) Install the EGR valve bracket See: Emission Control Systems/Exhaust Gas Recirculation/EGR Valve/Service and Repair/Installation. 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. CHECK FOR FUEL LEAK (a) Connect the Techstream to the DLC3. (b) Turn the ignition switch to ON and Techstream main switch ON. NOTICE: Do not start the engine. (c) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. (d) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. Components Tire Pressure Sensor: Service and Repair Components TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS Diagrams Trailer Brake Control Module: Diagrams Page 2067 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 264 Relay Box: Diagnostic Aids Continuity and Resistance Check CONTINUITY AND RESISTANCE CHECK Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. Page 7887 Solar Sensor: Testing and Inspection AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSPECTION 1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR) (a) Connect the battery's positive (+) lead to terminal 6 and the negative (-) lead to terminal 3, then measure the voltage according to the value(s) in the table below. Standard voltage: NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. HINT * As the inspection light is moved away from the sensor, the voltage decreases. * Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. (b) If the result is not as specified, replace the solar sensor. Page 8093 Removal SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BATTERY (a) Disconnect the cable from the positive (+) battery terminal. Page 146 Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. for Floor Shift Type: Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH (a) for Column Shift Type: Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) for Column Shift Type: Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 7. INSTALL INSTRUMENT SIDE PANEL RH (a) for Column Shift Type: Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation. (b) for Floor Shift Type: Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation. 8. INSTALL COWL SIDE TRIM BOARD RH (a) for Regular Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. (b) for Double Cab: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. (c) for CrewMax: Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation. 9. INSTALL FRONT DOOR SCUFF PLATE RH (a) for Regular Cab: Locations Overdrive Switch: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 2011 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 1516 Page 3609 Oxygen Sensor: Locations 1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION Page 1489 (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7): * If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: * The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. * When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. * Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ohms (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Page 667 Power Door Lock Switch: Testing and Inspection Door Control Switch (for Front RH) DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): INSPECTION 1. INSPECT DOOR CONTROL SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the control switch assembly. Components Control Module HVAC: Service and Repair Components AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: COMPONENTS Page 8282 (a) for LH Side: Attach the 4 clips to install the lower quarter trim panel lower. (b) for RH Side: Attach the 3 clips to install the lower quarter trim panel lower. (c) Install the seat belt anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (d) Attach the 2 claws to install the cover. 5. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation Service and Repair Vehicle Lifting: Service and Repair INTRODUCTION: REPAIR INSTRUCTION: VEHICLE LIFT AND SUPPORT LOCATIONS 1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE (a) The vehicle must be unloaded before jacking up / lifting up the vehicle. Never jack up / lift up a heavily loaded vehicle. (b) When removing heavy parts such as the engine and transmission, the center of gravity of the vehicle may shift. To stabilize the vehicle, place a balance weight in a location where it will not roll or shift, or use a mission jack to hold the jacking support. 2. NOTICE FOR USING 4 POST LIFT (a) Follow the safety procedures outlined in the lift's instruction manual. (b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels. (c) Use wheel chocks to secure the vehicle. 3. NOTICE FOR USING JACK AND SAFETY STAND (a) Work on a level surface. Use wheel chocks at all times. (b) Use safety stands with rubber attachments as shown in the illustration. (c) Set the jack and safety stands to the specified locations of the vehicle accurately. (d) When jacking up the vehicle, first release the parking brake and move the shift lever to N. (e) When jacking up the entire vehicle: (1) When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels. (2) When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels. (f) When jacking up only the front or rear wheels of the vehicle: (1) Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels. (2) Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels. (g) When lowering a vehicle that only has its front or rear wheels jacked up: (1) Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels. (2) Before lowering the rear wheels, make sure wheel chocks are behind the front wheels. Page 7430 Tire Pressure Module: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the ECU with the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the ECU connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 7. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration. 8. PERFORM INITIALIZATION (a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 9. CHECK TIRE PRESSURE AFTER REPAIRS Page 7959 Tire size: Must exceed the following dimensions Tires Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) CAUTION: Do not use tires with disc wheels except on the top and bottom. NOTICE: * As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. * Do not place SST connector under the tire because it could be damaged. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in the tires coming free due to the shock when the airbag is deployed. (f) Deploy the airbag. Page 8337 Impact Sensor: Testing and Inspection Side Airbag Sensor (for CrewMax) SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: * Cracks, dents or chips on the sensor housing. * Cracks or other damage to the connector. * Peeling off of the label or damage to the serial number. CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: * For removal and installation procedures of the side airbag sensor, be sure to follow the correct procedure. * If the airbags have deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. Page 361 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 6763 MJ1-NP1 Locations Ignition Relay: Locations MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION Locations Tire Pressure Monitor Receiver / Transponder: Locations TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION Page 1011 Parking Brake Warning Switch: Testing and Inspection PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION 1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking Brake System/Parking Brake Pedal/Service and Repair/Overhaul/Disassembly 2. CHECK PARKING BRAKE SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: (b) If the result is not as specified, replace the parking brake switch assembly. 3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking Brake System/Parking Brake Pedal/Service and Repair/Overhaul/Reassembly Center Airbag Sensor Assembly (for Floor Shift Type) Impact Sensor: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type) Components SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift Type): COMPONENTS Page 8429 Antenna, Navigation: Service and Repair Removal NAVIGATION: NAVIGATION ANTENNA: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 3. REMOVE NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly 4. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly 5. REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly 6. REMOVE DEFROSTER NOZZLE ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly 7. REMOVE NAVIGATION ANTENNA ASSEMBLY (a) Detach the clamp. (b) Remove the 2 screws and antenna. Page 303 Relay Box: Electrical Diagrams Engine Room R/B And Engine Room J/B Inner Circuit Page 9065 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 5385 Transfer Case Actuator: Locations JF1A Transfer Case JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION Center Power Outlet Socket (for Column Shift Type) Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Column Shift Type) Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS Page 6198 (a) Attach the claw to install the power outlet socket. (b) Connect the power outlet socket connector. 6. INSTALL CENTER FRONT SEAT ASSEMBLY (a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Center Seat)/Installation. 7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Power Seat)/Installation. 8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) HINT Use the same procedures described for the LH side. 9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Assembly (for Manual Seat)/Installation. 10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) HINT Use the same procedures described for the LH side. Components OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS Page 2437 Oil Pressure Sender: Diagrams Oil Pressure Switch Page 31 Central Control Module: Service and Repair Removal AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) for Column Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal. (b) for Floor Shift Type: Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal. 3. REMOVE MULTI-MEDIA INTERFACE ECU (a) Remove the nut. (b) Disconnect the connector and remove the multi-media interface ECU. 4. REMOVE MULTI-DISPLAY CONTROLLER BRACKET A (a) Remove the 2 bolts and multi-display controller bracket A. Page 974 Dimmer Switch: Service and Repair Installation METER: LIGHT CONTROL RHEOSTAT: INSTALLATION 1. INSTALL LIGHT CONTROL RHEOSTAT (a) Attach the 2 claws to install the rheostat. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Installation Page 8094 (b) Loosen the nut, move the stay off the battery, and remove the battery. 3. REMOVE FRONT AIRBAG SENSOR (a) Remove the nut and front airbag sensor from the body. (b) Disconnect the connector. Installation SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR (a) Check that the ignition switch is OFF. (b) Check that the cable is disconnected from the battery negative (-) terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Connect the connector. (d) Install the front airbag sensor with the nut. Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) NOTICE: * If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the front airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (e) Check that there is no looseness in the installation parts of the front airbag sensor. 2. INSTALL BATTERY Page 3753 (2) If the result is not as specified, replace the integration relay. 3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection Glass Breakage Sensor (for Floor Shift Type) Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Floor Shift Type) Components THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): COMPONENTS Removal THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH Front Axle Hub Bolt Wheel Fastener: Service and Repair Front Axle Hub Bolt Components AXLE: FRONT AXLE HUB BOLT: COMPONENTS Replacement AXLE: FRONT AXLE HUB BOLT: REPLACEMENT HINT * Use the same procedures for the LH side and RH side. Page 301 J/B No.6 Assembly - Instrument Panel Center Locations Shock Sensor: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 82 Power Mirror Control Module: Diagrams Page 6771 PJ1-TJ1 Locations Fog/Driving Lamp Switch: Locations LIGHTING: LIGHTING SYSTEM: PARTS LOCATION Page 7326 (a) Pack the upper arm ball joint with MP grease. Grease capacity: 5.0 to 7.0 g (0.176 to 0.247 oz.) (b) Using a snap ring expander, install the dust cover set ring. 2. INSTALL FRONT SUSPENSION UPPER ARM BUSH (a) Using SST and a press, press in a new bush. SST : 09710-26011 09710-05061 Page 1564 Tire Pressure Warning Reset Switch: Service and Repair Removal TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL 1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal 2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal 4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal 6. REMOVE TIRE PRESSURE WARNING RESET SWITCH (a) Disconnect the switch connector. (b) Detach the 2 claws and remove the reset switch. Recall 10V017000: Accelerator Pedal Sticking Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4 2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor North America, Inc. MFR'S REPORT DATE: January 21, 2010 NHTSA CAMPAIGN ID NUMBER: 10V017000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly: Pedal/Linkage POTENTIAL NUMBER OF UNITS AFFECTED: ? SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010 Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor assembly, the sliding surface of the lever may become smooth during vehicle operation. In this condition, if condensation occurs on the surface, as may occur from heater operation (without A/C) when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase, which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the worst case, mechanically stuck in a partially depressed position. CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash. REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners may contact Toyota at 1-800-331-4331. NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 5123 3. Inspect the front differential support bolt for separation. Repair Procedure 1. If the differential support bolt is separated perform the five steps below. NOTE If there is NO damage to the differential support bolt, this TSB does NOT apply. Continue diagnosis to isolate the cause of the condition. A. Remove the differential support bolt. Refer to the Technical Information System (TIS) applicable model and model year Repair Manual: B. Clean the bracket and surrounding area. C. Install the NEW differential support bolt. Refer to TIS applicable model and model year Repair Manual: Torque: 120 N*m (1224 kgf*cm, 89 ft*lbf) Page 655 Hood Sensor/Switch (For Alarm): Diagrams Page 6709 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Locations Power Distribution Relay: Locations Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 6608 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT The diagnostic system in the TOYOTA TUNDRA has various functions. * The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. * Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. * By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. Locations Alarm Horn Relay: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Locations Transmission Position Switch/Sensor: Locations A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS LOCATION Page 6602 (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Standard resistance (Fig. 2): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3): * If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. Page 8348 NOTICE: * If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. * When installing the front airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (e) Check that there is no looseness in the installation parts of the front airbag sensor. 2. INSTALL BATTERY (a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the battery in place. (b) Connect the cable to the positive (+) battery terminal. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System. Page 9106 Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the electrical circuit. 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. Finding A Short Circuit FINDING A SHORT CIRCUIT Page 8286 (c) Remove the 2 bolts and seat belt. Installation SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): INSTALLATION HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Align the vehicle's claws with the seat belt retractor positioning holes. (b) Install the seat belt with the 2 bolts. HINT First install bolt A, and then install bolt B. for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) (c) Install the shoulder anchor with the bolt. Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation 3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY Page 1233 Transmission Position Switch/Sensor: Diagrams Page 5918 Wheel Speed Sensor: Service and Repair Rear Speed Sensor Components BRAKE CONTROL: REAR SPEED SENSOR: COMPONENTS Removal BRAKE CONTROL: REAR SPEED SENSOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Page 7649 (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal 1 of connector C. Standard voltage (Fig. 4): * If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6): HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Page 8248 Components SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): COMPONENTS Removal SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): REMOVAL HINT * Use the same procedures for the LH side and RH side. * The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Page 2032 Driver Side J/B - Cowl Side Left Page 291 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 7646 INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: * As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. * Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension Page 3322 Components Knock Sensor: Service and Repair Components 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS Page 6292 Engine Room R/B, J/B - Engine Compartment Left Page 5549 Four Wheel Drive Selector Switch: Service and Repair Removal JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal 2. REMOVE 4WD CONTROL SWITCH (a) Detach the 3 claws to remove the switch. Page 3078 Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR Insert the terminal. HINT: Make sure the terminal is positioned correctly. Insert the terminal until the locking lug locks firmly. Insert the terminal with terminal retainer in the temporary lock position. Page 7366 Page 2942 Knock Sensor: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL 1. REMOVE INTAKE MANIFOLD (a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal. 2. REMOVE SEPARATOR CASE (a) Remove the 4 bolts and separator case. 3. REMOVE KNOCK SENSOR (a) Disconnect the 4 knock sensor connectors. (b) Remove the 4 bolts and 4 knock sensors. Page 732 Seat Heater Switch: Diagrams Seat Heater Switch Page 4291 1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or excessive lock-up operation at freeway speeds about 50 - 60 mph. 2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3. 3. Flash reprogram the ECM (PCM). NOTE ^ 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 the Technical Information System (TIS), Diagnostics - Battery. Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update. 4. Start the engine and warm it up to normal operating temperature before test driving. 5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer to the Technical Information System (TIS) 2010 Tundra Repair Manual: Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic Transmission/Transaxle: Automatic Transmission System: Initialization" 6. Install the Authorized Modifications Label. A. Using a permanent marker enter the following information on the label: ^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER] Page 8887 Collision Avoidance Module: Diagrams Page 6827 Components Parking Assist Control Module: Service and Repair Components PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: COMPONENTS Page 1652 Power Window Switch: Service and Repair Rear Power Window Switch Components WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: COMPONENTS Page 1708 (b) * for 5 leaf spring 6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Install the camber-caster-kingpin gauge or place the front wheels on the center of the wheel alignment tester. Page 6281 General Information INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL INFORMATION * A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. 1. TROUBLESHOOTING PROCEDURES * The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. * Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. * It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. * In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. * To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU. DIAGNOSTIC TESTER 2. DESCRIPTION System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to check for a malfunction and perform repairs. HINT *: Techstream is the name for the diagnostic tester in North America. 3. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Page 7749 Page 7832 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSPECTION 1. INSPECT AMBIENT TEMPERATURE SENSOR (a) Measure the resistance according to the value(s) in the table below. Standard resistance: NOTICE: * Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. * When measuring the resistance, the sensor temperature must be the same as the ambient temperature. HINT As the temperature increases, the resistance decreases (see the graph). (b) If the result is not as specified, replace the ambient temperature sensor. Page 8460 Page 4091 (d) Remove the gasket from the No. 2 EGR pipe. NOTICE: Be careful not to damage the installation surface of the gaskets. (e) Remove the gasket from the intake manifold. 7. REMOVE EGR INLET (a) Remove the 2 bolts, EGR inlet and gasket. NOTICE: Be careful not to damage the installation surface of the gaskets. 8. REMOVE NO. 3 EGR PIPE SUB-ASSEMBLY (a) Remove the 2 nuts, No. 3 EGR pipe and gasket. NOTICE: Be careful not to damage the installation surface of the gaskets. 9. REMOVE EGR VALVE BRACKET (a) Remove the 3 bolts and EGR valve bracket. Page 7056 (c) * for 5 leaf spring Standard caster inclination (unloaded vehicle): for Regular Cab of Standard Deck Page 4277 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 9009 The short lies between the connector where the test light stays lit and the connector where the light goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: 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.) 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) PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. DISCONNECT CONNECTOR Page 3646 Body Control Module: Diagrams Page 3233 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 4355 NOTICE: * Make sure that there are no scratches or foreign matter in or around the insertion hole of the delivery pipe. * When inserting the injector, be careful not to damage the O-ring. * Attach the part of the injector labeled B between the parts of the delivery pipe labeled A. (f) Check that each injector is installed to the delivery pipe facing the direction shown in the illustration. 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY LH (a) Install the 2 delivery pipe spacers and 4 insulators to the cylinder head LH. (b) Install the delivery pipe (with injectors) to the cylinder head LH. (c) Install the 2 bolts. Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) NOTICE: Make sure that the part of the injector labeled B is between the parts of the delivery pipe labeled A. (d) Connect the No. 7 wire harness connector. 3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY RH Page 6335 Page 1701 (a) Bounce the vehicle up and down at the corners to stabilize the suspension, and then inspect the toe-in. Standard toe-in (unloaded vehicle): for Regular Cab of Standard Deck Standard toe-in (unloaded vehicle): for Regular Cab of Long Deck Standard toe-in (unloaded vehicle): for Double Cab of Standard Deck Page 1375 Impact Sensor: Diagrams Door Side Airbag Sensor Page 8241 (a) Remove the nut and bolt, and then detach the 2 claws and remove the seat belt. Installation SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): INSTALLATION 1. INSTALL CENTER FRONT SEAT BELT ASSEMBLY RH (a) Align the seat frame's claws with the seat belt retractor positioning holes. (b) Install the seat belt with the nut and bolt. HINT First install the bolt, and then install the nut. for bolt - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) for nut - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf) 2. INSTALL FRONT SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 3. INSTALL FRONT SEATBACK BOARD SUB-ASSEMBLY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 4. INSTALL SEAT FASTENER COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 5. INSTALL CENTER FRONT SEAT ARMREST COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 6. INSTALL FRONT SEAT TRAY See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 7. INSTALL RECLINING REMOTE CONTROL BEZEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 8. INSTALL LOWER FRONT SEAT SHOULDER BELT COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 9. INSTALL UPPER REAR SEATBACK LOCK BEZEL See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 10. INSTALL FRONT SEAT SHOULDER BELT COVER See: Body and Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly (for Center Seat)/Reassembly 11. INSTALL FRONT SEAT HEADREST ASSEMBLY Page 6955 Instrument Panel (Floor Shift) Instrument Panel (Column Shift) Page 348 Parts Information Required Tools & Equipment Repair Procedure 1. Confirm the condition matches the Introduction. Page 6269 "Case2" 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 Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Wiring Color Codes Abbreviations Used Within Diagrams Abbreviations Used Within Diagrams Page 5300 Use the same installation procedure for the universal joint spider bearing on the opposite side. (i) Temporarily install the spider and 2 universal joint spider bearings into the shaft yoke. (j) Using SST, press the universal joint spider bearing into the shaft yoke until the groove can be seen. SST : 09950-40011 09951-04020 09952-04010 09953-04020 09954-04020 09955-04051 09957-04010 SST : 09950-60010 09951-00290 SST : 09336-16010 NOTICE: * Position SST (09336-16010) so that the cutout faces the shaft tube. * Confirm that the universal joint spider moves smoothly while pressing in the bearing. (k) Using needle-nose pliers, install the previously selected snap ring into the groove on the shaft yoke. HINT Use the same installation procedure for the universal joint spider bearing on the opposite side. 2. INSTALL NO. 1 CENTER SUPPORT BEARING ASSEMBLY (for 3 Joint Type) (a) Coat the splines of the intermediate shaft with MP grease. (b) Install the center support bearing to the intermediate shaft. Page 2825 HINT The wavelength becomes shorter as the engine rpm increases. (f) WAVEFORM 5: HINT * The wavelength becomes shorter as the engine rpm increases. * The waveforms and amplitudes displayed differ slightly depending on the vehicle. (g) WAVEFORM 6: HINT The wavelength becomes shorter as engine rpm increases. (h) WAVEFORM 7: Page 6598 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR Voltage Check VOLTAGE CHECK Page 7605 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Page 2834 Engine Control Module: Service and Repair Removal 1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL 1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Removal 2. REMOVE AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and Repair/Removal 3. DISCONNECT CONNECTOR HOLDER BLOCK (a) Remove the connector holder block cover. (b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in the next step. 4. REMOVE ECM (a) Disconnect the wire harness clamp. (b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration. NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before disconnecting the connectors. Failure to do this may cause the connectors to break. (c) Disconnect the 2 connectors. (d) Remove the 4 bolts and ECM. 5. REMOVE GASKET (a) Peel off the rubber part of the gasket. Page 2189 Tire Pressure Module: Service and Repair Installation TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the ECU with the 2 nuts. Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf) (b) Connect the ECU connector. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation 4. INSTALL COWL SIDE TRIM BOARD RH (a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation. HINT Use the same procedures described for the LH side. 6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation. HINT Use the same procedures described for the LH side. 7. REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID See: Testing and Inspection/Programming and Relearning/Registration. 8. PERFORM INITIALIZATION (a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization. NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization. 9. CHECK TIRE PRESSURE AFTER REPAIRS Page 5893 Traction Control Switch: Locations From 11/2009 BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION Locations Lock Cylinder Switch: Locations THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION Page 3485 Standard resistance: NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (BUS BUFFER ECU) OK -- REPLACE BUS BUFFER ECU 10. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR) (a) Disconnect the J46 center airbag sensor connector. (b) Reconnect the cable to the negative (-) battery terminal. (c) Select "CAN Bus Check" on the Techstream. Result B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU) A -Continue to next step. 11. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR BRANCH WIRE) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Page 6998 J/B No.4 - Instrument Panel Center Page 6211 (a) for AC Power Supply: Disconnect the clamp. (b) Remove the 3 screws and bezel. 3. REMOVE REAR POWER OUTLET SOCKET (for Standard) (a) Detach the claw and remove the power outlet socket. 4. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard) (a) Detach the 2 claws and remove the power outlet socket cover. 5. REMOVE REAR POWER POINT SOCKET (for AC Power Supply) (a) Detach the 2 claws and remove the power outlet socket. Page 2481 Cylinder Head Gasket: Service and Repair Cylinder Head Gasket (for Bank 2) Components 1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 2): COMPONENTS Removal 1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 2): REMOVAL 1. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Remove the exhaust manifold RH See: Exhaust System/Exhaust Manifold/Service and Repair/Removal. 2. REMOVE CAMSHAFTS (for Bank 2) (a) Remove the camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Camshaft (for Bank 2)/Removal. 3. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY (a) Remove the 16 valve rocker arms from the cylinder head. HINT Arrange the removed parts in the correct order. 4. REMOVE VALVE LASH ADJUSTER ASSEMBLY (a) Remove the 16 valve lash adjusters from the cylinder head. HINT Arrange the removed parts in the correct order. 5. REMOVE VALVE STEM CAP (a) Remove the 16 valve stem caps from the cylinder head. HINT Arrange the removed parts in the correct order. 6. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH (a) Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration. Page 9247 Page 6288 (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: * Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. * Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: * Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. * Never apply water directly onto the electronic components. HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Testing and Inspection Parking Assist Switch: Testing and Inspection PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSPECTION 1. INSPECT DRIVE MONITOR SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: (b) If the result is not as specified, replace the monitor switch. (c) Inspect the switch illumination. (1) Connect the positive (+) lead of the battery to terminal 1 (ILL+) and the negative (-) lead to terminal 6 (ILL-). (2) Check that the LED comes on. OK: LED comes on. (3) If the result is not as specified, replace the monitor switch. Page 7635 Remove the blown fuse and disconnect all loads of the fuse. Connect a test light in place of the fuse. Establish conditions in which the test light comes on. Example: - [A] - Ignition SW on - [B] - Ignition SW and SW1 on - [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2) Disconnect and reconnect the connectors while watching the test light. Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Components BRAKE CONTROL: BRAKE ACTUATOR: COMPONENTS Removal BRAKE CONTROL: BRAKE ACTUATOR: REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. 2. DISCONNECT VSC ACTUATOR CONNECTOR (a) Pull the release bar and disconnect the VSC actuator connector. 3. REMOVE BRAKE TUBE (a) Use tags or make a note to identify the reconnection locations. Page 7951 Tire size: Must exceed the following dimensions Width 185 mm (7.28 in.) Inner diameter 360 mm (1.18 ft.) (2) Tie the front passenger airbag to the tire with several wire harnesses. CAUTION: * Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the front passenger airbag may become loose due to the shock when the airbag is deployed. * Always tie down the front passenger airbag with the airbag deployment side facing inside the tire. NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (e) Place the tires. (1) Place at least 2 tires under the tire which the front passenger airbag is tied to. (2) Place at least 2 tires over the tire which the front passenger airbag is tied to. The top tire should have a disc wheel installed. NOTICE: * Do not place the SST connector under the tire because it could be damaged. * As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are planning to throw away. * As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw away. (3) Tie the tires together with 2 wire harnesses. Page 3464 Information Bus: Testing and Inspection LIN Communication System MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: HOW TO PROCEED WITH TROUBLESHOOTING HINT * Use these procedures to troubleshoot the LIN communication system. * *: Use the Techstream. 1. VEHICLE BROUGHT TO WORKSHOP NEXT -- Continue to next step. 2. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT -- Continue to next step. 3. CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Using the Techstream, inspect the CAN communication function to ensure there are no malfunctions in the CAN communication system See: Initial Inspection and Diagnostic Overview/CAN Communication System/How to Proceed With Troubleshooting. B -- GO TO CAN COMMUNICATION SYSTEM See: Initial Inspection and Diagnostic Overview/CAN Communication System/How to Proceed With Troubleshooting A -- Continue to next step. 4. PROBLEM SYMPTOMS TABLE (a) Refer to the problem symptoms table See: Symptom Related Diagnostic Procedures/LIN Communication System/Problem Symptoms Table. B -- Go to step 6 A -- Continue to next step. 5. OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Terminals of ECU See: Pinout Values and Diagnostic Parameters/LIN Communication System (b) Data List / Active Test See: Scan Tool Testing and Procedures NEXT -- Continue to next step. 6. REPAIR OR REPLACE NEXT -- END How to Proceed With Troubleshooting Page 7821 (a) for Manual Air Conditioning System: Disconnect the 2 connectors. (b) for Automatic Air Conditioning System: Disconnect the 3 connectors. (c) Remove the 2 screws and amplifier. Page 6110 (b) Check the movement of the clutch pinion gear. (1) Rotate the clutch pinion gear clockwise, and check that it turns freely. (2) Try to rotate the clutch pinion gear counterclockwise, and check that it locks. If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly. 7. INSPECT MAGNET STARTER SWITCH ASSEMBLY (a) Inspect the pull-in coil. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the magnet starter switch assembly. (b) Inspect the holding coil. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance: (2) If the result is not as specified, replace the magnet starter switch assembly. Page 9220 (b) Attach the 2 clips to install the front armrest upper base panel. 8. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (a) Attach the 4 claws to install the bezel plug. 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System.